Method of producing a laminate

Abstract

A continuous method of forming a laminate comprising a deformable layer, the use of the laminate in a wound dressing and an apparatus for the method are disclosed. The laminate comprises discrete deformable first layers and a substantially continuous second layer. The method comprises supplying a substantially continuous layer of deformable material at a first feed rate and a substantially continuous second layer at a second feed rate, wherein the second feed rate is greater than the first feed rate; cutting the substantially continuous layer of deformable material into discrete portions; transferring the discrete portions of the deformable first layer to a transfer device; transferring the discrete portions of the deformable first layer from the transfer device to the surface of the second layer at predetermined locations on the surface of the second layer such that the surface of the deformable layer is in contact with the surface of the second layer, wherein the method comprises a device for adjusting the predetermined locations using a feedback loop comprising a detector device and an adjustment device.

Description

Technical Field

[0001] Embodiments of this disclosure relate to methods for producing laminated materials including deformable layers, their use in wound dressings, and equipment used in methods for producing laminated materials including deformable layers. Background Technology

[0002] Wound dressings used in the medical device industry typically consist of one or more absorbent pads arranged to form islands on a larger adhesive-coated membrane or fabric web. The construction of these multi-layered articles is relatively complex. In particular, the precise cutting and positioning of the material used in the islands can be challenging during manufacturing, especially if the material is stretchable and / or of varying thickness.

[0003] Traditionally, padding material is unrolled from a roll and cut into individual sections. The cut sections are then transferred to a web coated with adhesive. Both the cutting and transfer processes can introduce tension into the padding material. This can have a stretching effect on the padding material. This can result in pads that are too large, too small, and / or misaligned.

[0004] An alternative method is to run the pad feed at the same web speed as the main film or fabric web. In this technique, the pad may be cut off from its web in such a way that there is waste material from the pad. However, this process can generate extremely high levels of waste.

[0005] Therefore, it is desirable to develop a process to mitigate one or all of these problems. Summary of the Invention

[0006] The embodiments disclosed herein relate to a continuous method for forming a laminate, wherein the laminate includes a discrete deformable first layer having a first surface and a second surface, and a substantially continuous second layer having a first surface and a second surface, wherein the method includes supplying the substantially continuous layer of deformable material at a first feed rate and the substantially continuous second layer at a second feed rate, wherein the second feed rate is greater than the first feed rate; cutting the substantially continuous film of deformable material into discrete portions; transferring the discrete portions of the deformable first layer to a transfer device; transferring the discrete portions of the deformable first layer from the transfer device to the first surface of the second layer at predetermined discrete positions on the first surface of the second layer, such that the second surface of the deformable layer contacts the first surface of the second layer to form a laminate, wherein a feedback loop is used to control the predetermined positions, wherein the feedback loop includes a detection device and an adjustment device.

[0007] As used herein, the term "substantially continuous" refers to components of a process, such as the first or second layer of a laminate, that are provided in a long, continuous manner, such as on rollers. The term "substantially" is included because any component must inevitably have a finite length. Regarding the process, the term "substantially continuous" is used in its conventional sense and means that the manufacturing process does not substantially require pausing to perform one or more steps. Regarding the travel rate, the term "substantially constant" is used in its conventional sense and means that the rate remains substantially unchanged throughout the manufacturing process.

[0008] The feedback loop can be a closed feedback loop. A deformable first layer is applied to the second layer at a clamping point. The clamping point can be any suitable point on a discrete portion of the deformable first layer, for example, at the leading or trailing edge of a discrete portion of the deformable first layer relative to its direction of movement. The feedback loop can cause the clamping point of the second layer to be adjusted relative to the position of the discrete portion of the deformable first layer on the transfer device. The position of either the deformable first layer or the position of the second layer can be adjusted.

[0009] The detection device can be any suitable detection device, such as a laser detector or a vision inspection device. The detection device can detect the position of discrete portions of the deformable first layer relative to the second layer downstream of the clamping point.

[0010] The adjusting device can be any suitable adjusting device, such as a servo motor or a cam and follower. Alternatively, the adjusting device can be a conveyor belt, such as a vacuum conveyor, a pusher peg conveyor, or a combination of different types of conveyor belts.

[0011] The feedback loop can cause the clamping position of the second layer to be vertically adjusted relative to the position of the discrete portion of the deformable first layer on the transfer device.

[0012] Vertical adjustment can be achieved using any suitable device. Suitable devices may include servo motors or cams and followers. The adjustment device can adjust the position of discrete portions of the deformable first or second layer. The position of the second layer can be adjusted by adjusting the position of the device that conveys the second layer, such as by adjusting the position of the rollers or flight rollers.

[0013] The feedback loop can cause the clamping position of the second layer relative to the discrete portion of the deformable first layer on the transfer device to be adjusted horizontally.

[0014] Horizontal adjustment can be achieved using any suitable device. Suitable devices may include conveyor belts or servo motors. Conveyor belts may include vacuum conveyors, push rod conveyors, or combinations of different types of conveyor belts. The device can adjust the position of discrete portions of the deformable first or second layer. Adjusting the position of the second layer can be achieved by adjusting the position of the device conveying the second layer, such as by adjusting the position of rollers or traction rollers.

[0015] The transfer device can travel at essentially the same speed as the deformable first layer.

[0016] During cutting, if deformable material is transferred to a transfer device traveling at a faster rate than the feed rate, the deformable material will typically be under tension and may therefore deform. This can be exacerbated when the deformable material has greater thickness and / or ductility. Without being bound by theory, by transferring discrete portions of the deformable material to a transfer device traveling at substantially the same rate as the first feed rate, these discrete portions will be subjected to little or no tension or deformation when applied to the first surface of the second layer. This allows the discrete portions to be placed more accurately and consistently on the first surface of the second layer. The transfer device preferably travels at a substantially constant rate, i.e., the rate of travel of the transfer device remains substantially constant throughout the process.

[0017] Typically, the first feed rate can range from 0.7 m / min to 75.0 m / min, typically within the ranges of 1.0 m / min to 55.0 m / min, 10.0 m / min to 30.0 m / min, or 15.0 m / min to 25.0 m / min, and is usually about 20 m / min. Typically, the second feed rate can be approximately twice the first feed rate. The second feed rate can range from 2.0 m / min to 105.0 m / min, typically within the ranges of 20.0 m / min to 60.0 m / min, 30.0 m / min to 50.0 m / min, and is usually about 40 m / min.

[0018] The transfer device can be any suitable transfer device, such as a transfer roller, conveyor belt, or vacuum transfer belt, or a combination thereof. In some embodiments, the transfer device is a vacuum roller that rotates at a rate such that the outer surface of the cylinder travels substantially at a first feed rate. Preferably, the vacuum roller rotates at a substantially constant rate such that the outer surface of the cylinder travels substantially at a substantially constant first feed rate. The vacuum roller can be used as an anvil of a cutting device for cutting substantially continuous layers of deformable material into discrete portions.

[0019] Deformable materials can be cut using any suitable cutting device. Preferably, the cutting device is a blade, such as a knife, preferably a steel or carbide sheeter knife. Preferably, the cutting device is a cutting device attached to a roller, preferably a blade such as a knife, preferably a carbide sheeter knife attached to a roller. Alternatively, the cutting device can be a complete rotary die. If such a rotary die is used, non-rectangular / shaped pads can be produced. Any waste generated can then be removed from the die.

[0020] In some embodiments, the transfer device is a transfer roller, and the cutting device is able to be attached to the roller. Preferably, the transfer roller serves as an anvil for the cutting device. More preferably, the transfer device is a vacuum roller, and the cutting device is a blade attached to the roller. Most preferably, the vacuum roller serves as an anvil for the blade attached to the roller.

[0021] The method may include a second transfer device. The second transfer device may travel substantially at a second feed rate, wherein discrete portions of the deformable material are first transferred to a first transfer device and subsequently to a second transfer device; that is, the second transfer device may accelerate the feed rate of the discrete portions from a first feed rate to a substantially second feed rate. For example, the discrete portions may be transferred to a first transfer roller traveling substantially at a first feed rate and subsequently to a second roller traveling substantially at a second feed rate. Alternatively, the second transfer device may travel substantially at a first feed rate. For example, the discrete portions may be transferred to a first transfer roller traveling substantially at a first feed rate, then subsequently to a vacuum transfer belt traveling substantially at a first feed rate, and then to a second layer traveling at a second feed rate. The transfer devices may travel at a substantially constant rate.

[0022] The second transfer device can be a transfer roller, a conveyor belt or vacuum transfer belt, a reciprocating applicator, or a combination thereof. The second transfer device can be a transfer roller with a diameter larger than that of the first transfer roller, preferably having a diameter such that its circumference is approximately twice that of the first roller. The second transfer device can be a vacuum conveyor, a push rod conveyor, or a combination of different types of conveyors or conveyor belts. For example, a push rod conveyor combined with a suspended vacuum conveyor, or a conveyor belt combined with a suspended vacuum conveyor. The transfer roller, vacuum conveyor, push rod conveyor, or combination of different types of conveyors or conveyor belts can be used in conjunction with a reciprocating applicator, or may itself include a reciprocating device. The reciprocating motion device can be any suitable reciprocating motion device, such as a servo motor or a cam and follower.

[0023] The first transfer device can be a vacuum roller, and the second transfer device can be a vacuum roller with a diameter larger than that of the first transfer device's vacuum roller. The first transfer device can be a vacuum roller, and the second transfer device can be a vacuum transfer belt, preferably combined with a vertical reciprocating applicator (such as a cam and a follower) to lift the pad onto the second layer. The first transfer device can be a vacuum roller, and the second transfer device can be a push-rod conveyor for creating spacing of discrete portions of deformable material, combined with a suspended vacuum conveyor to transfer the pad from the push-rod conveyor to the second layer. The first transfer device can be a vacuum roller, and the second transfer device can be a vacuum conveyor, combined with a suspended vacuum conveyor to transfer the pad from the vacuum conveyor to the second layer.

[0024] When the second transfer device is a vacuum conveyor, the vacuum conveyor can apply a vacuum to discrete portions of the deformable material along the entire length of the conveyor, or the vacuum can be sealed near the transfer point to prevent stretching at the point where the discrete portions of the deformable material are applied to the second layer. Preferably, the portion of the belt where the vacuum is sealed is at least as long as the discrete portion. The belt of the vacuum conveyor can be made of any suitable material, but preferably has sufficient friction to transport the deformable material but low enough to allow transfer without deformation. The vacuum conveyor belt can be formed of polymeric materials. Suitable polymeric materials include polyurethane, silicone, vinyl polymers including polyvinyl chloride, and nitrile rubber. The surface of the belt can be textured. Textured surfaces are considered particularly advantageous for the transport and subsequent transfer of fibrous and foam materials, without being bound by theory.

[0025] The second layer can be conveyed in this process using any suitable device. Typically, rollers such as large-diameter assembly drums or traction rollers can be used to convey the second layer. The rollers can travel at a substantially constant rate, preferably substantially at a second feed rate.

[0026] The method may also include additional upstream or downstream steps. Such steps may be suitable for the intended purpose of the laminate. For example, when the laminate is used as a wound dressing, the method may further include applying a release liner to the wound contact surface upstream or downstream of the production of the laminate according to the first embodiment. An additional layer may be added to the laminate produced by the method according to the first embodiment downstream of the production of the laminate according to the first embodiment. Additionally or alternatively, individual dressings may be cut out and packaged downstream of the production of the laminate according to the first embodiment.

[0027] Preferably, the laminate is suitable for wound dressings. The laminate can form components of a wound dressing. The laminate can form the wound contact layer of a wound dressing. The laminate can form the backing layer, i.e., the outermost layer, of a wound dressing.

[0028] The deformable layer is any suitable deformable layer for its intended purpose. When the laminate is used in a wound dressing, the deformable layer can be an absorbent layer, preferably a foam layer. The foam can be any suitable polymeric foam. The foam is suitably a highly conformable hydrophilic foam, suitably an open-cell foam, and more suitably a mixture of open-cell and closed-cell foams. It is desirable for the foam layer to rapidly absorb wound exudate. This rapid absorption prevents undesirable pooling of exudate between the dressing and the wound.

[0029] The deformable layer itself can be a multilayer laminate. When the laminate is used in wound dressings, the deformable layer may include a masking layer. The masking layer may include incisions or windows. Windows provide a means of observing the level of exudate in the wound dressing while still providing a barrier to most of the exudate to improve patient comfort. The masking layer may be a completely opaque polymer film with incision windows or perforations.

[0030] The second layer may have an adhesive layer applied to one or more surfaces of the second layer. The adhesive can adhere the first layer to the second layer.

[0031] The adhesive can be any adhesive suitable for the end use of the laminated material. In the case of the laminated material being used for wound dressings, preferably, one or more adhesive layers in the adhesive layer can be pressure-sensitive adhesives. Suitably, the pressure-sensitive adhesive layer can be formed from a biocompatible adhesive. Suitable adhesives include silicone, hot melt, hydrocolloid, or acrylic-based adhesives. Preferably, the pressure-sensitive adhesive is applied to the first surface of the second layer.

[0032] Preferably, one or more adhesive layers in the adhesive layer can be wound contact adhesives. The wound contact adhesive can be a silicone or acrylic adhesive, typically a silicone adhesive. In a particularly preferred embodiment, a pressure-sensitive adhesive can be applied to a first surface of the second layer, and a silicone wound contact adhesive can be applied to a second surface of the second layer. When the adhesive is applied to the second surface of the second layer, the adhesive is typically covered by a removable release liner.

[0033] The release liner can be any suitable material, typically a polymer film such as a polypropylene film or coated paper. The release liner can be a silicone-coated release liner. The release liner can have a thickness of 50 micrometers to 200 micrometers.

[0034] The second layer can be any suitable layer, preferably a substantially non-deformable layer. Preferably, the second layer comprises a polymer film. The polymer film can be formed from any suitable polymer, such as polyurethane, silicone, ethyl vinyl acetate, polyethylene, polypropylene, or polyester, or combinations thereof. The second layer can be a wound contact layer.

[0035] The wound contact layer may include a perforated wound-side adhesive, which may be a silicone adhesive or a low-tack adhesive, to minimize skin trauma during removal. The second layer itself may be perforated. Preferably, the perforations in the second layer and the adhesive applied to the second layer coincide. The second layer may be a perforated polyurethane film coated with a skin-compatible adhesive, such as a pressure-sensitive acrylic adhesive or a silicone adhesive.

[0036] Each layer of a laminate can be removed as a single, complete layer; however, it should be understood that each layer of a laminate may itself comprise multiple layers and include more than one different material.

[0037] When the laminate is suitable for use as a backing layer in a wound dressing, the second layer may include a polymer film. The polymer film may be formed from any suitable polymer, such as polyurethane, silicone, ethyl vinyl acetate, polyethylene, polypropylene, or polyester, or combinations thereof. The backing layer may be a liquid-impermeable, moisture-permeable, and air-permeable membrane that allows moisture to evaporate from the dressing.

[0038] According to another aspect of the invention, a laminated material produced according to the method of the first aspect is provided. According to yet another aspect of the invention, a wound dressing is provided comprising the laminated material produced according to the method of the first aspect. The laminated material may have any of the preferred features described above with respect to the first aspect of the invention.

[0039] According to another aspect of the present invention, an apparatus for performing the method of the present invention is provided.

[0040] The device includes: a cutting device for cutting deformable material; a transfer device adapted to transfer the deformable material to the surface of a second material; and a closed feedback loop including a detection device and an adjustment device, wherein the closed feedback loop detects the position of the deformable material on the second material at a downstream position of the transfer device and adjusts the position of the transfer device accordingly.

[0041] The device may include a first transfer device for transferring deformable material at a first rate and a second transfer device for transferring deformable material at a second rate, wherein the second rate is faster than the first rate, and wherein the first transfer device is capable of transferring deformable material to the second transfer device.

[0042] The components of the device may have the preferred features described above with respect to the method of the first embodiment.

[0043] Preferably, the apparatus further includes means for ensuring that the first deformable layer, the second layer, and subsequent laminates follow a predetermined path through the apparatus used for the method. Suitable means will be known to those skilled in the art, but include rollers, blades, and conveyor belts.

[0044] The apparatus may also include additional upstream or downstream components. Such components may be suited to the intended purpose of the laminate. For example, when the laminate is used as a wound dressing, the apparatus may also include means for applying a release liner to the wound contact surface upstream of the production of the laminate according to the first embodiment. Additional lamination means for adding additional layers to the laminate produced by the method according to the first embodiment, cutting means for cutting individual dressings, and packaging means for packaging individual dressings may be present downstream of the production of the laminate according to the first embodiment.

[0045] The device may include a processor and memory, the memory storing instructions that, when executed by the processor, cause the device to perform any of the methods disclosed herein.

[0046] Further preferred features of the components required in the aforementioned apparatus are defined above with respect to the first and second aspects, and can be combined in any combination.

[0047] According to another aspect of the invention, a computer-readable storage medium is provided comprising instructions that, when executed, cause a device as defined in the preceding aspects to perform any method defined herein. The computer-readable storage medium may be non-transitory. Attached Figure Description

[0048] Embodiments of this disclosure will now be described below by way of example only with reference to the accompanying drawings, in which:

[0049] Figure 1 A dressing comprising multiple laminated layers is shown according to some embodiments.

[0050] Figure 2 The apparatus shown is adapted for use according to some embodiments and is applicable to methods according to some embodiments.

[0051] Figure 3 Additional equipment is shown according to some embodiments and applicable to the methods according to some embodiments.

[0052] Figure 4 Additional equipment is shown according to some embodiments and applicable to the methods according to some embodiments.

[0053] Figure 5 Additional equipment is shown according to some embodiments and applicable to the methods according to some embodiments.

[0054] Figure 6 Additional equipment is shown according to some embodiments and applicable to the methods according to some embodiments.

[0055] Figure 7 Additional equipment is shown according to some embodiments and applicable to the methods according to some embodiments.

[0056] In the accompanying drawings, corresponding reference numerals denote corresponding parts. Those skilled in the art will appreciate that the elements in the drawings are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some elements in the figures may be exaggerated relative to other elements to aid in understanding the various exemplary embodiments. Furthermore, common but well-known elements that are useful or necessary in commercially viable embodiments are generally not depicted to minimize obstruction of the view of these various exemplary embodiments. Detailed Implementation

[0057] Figure 1 An exploded perspective view of a wound dressing according to an embodiment of the present disclosure is shown. The wound dressing 100 comprises multiple layers constructed in a generally layered manner to form a dressing having a relatively planar form. The wound dressing 100 includes a boundary region 110 extending around the outer periphery of the dressing. A central region may be predetermined to suit a specific wound or a specific wound type. Here, the boundary region has the general function of providing a region for sealing the skin around the wound site to form a sealed cavity above the wound site. The central region is the location of other functional elements of the wound dressing.

[0058] The dressing 100 includes a top membrane 102, a superabsorbent layer 103, a perforated wound contact layer 101, an absorbent material layer 104 of suitable size to cover a wound of a recommended size corresponding to the size of the selected particular dressing, and a masking layer 105 that allows partial masking of the top surface of the superabsorbent, in which colored exudate will be retained.

[0059] The wound contact layer 101 may be a perforated polyurethane membrane coated with a skin-compatible adhesive, such as pressure-sensitive acrylic adhesive or silicone adhesive. The skin-compatible adhesive is applied to the underside of layer 101, i.e., the side that contacts the patient.

[0060] The absorbent layer can be a foam layer, and the foam can be any suitable polymer foam. The foam is suitably a highly conformable hydrophilic foam, suitablely an open-cell foam, or a mixture of open-cell and closed-cell foam.

[0061] The foam layer is expected to quickly absorb wound exudate. This rapid absorption prevents undesirable accumulation of exudate between the dressing and the wound.

[0062] The masking layer 105 is a completely opaque polymer film with cut-out windows or perforations to make the superabsorbent layer visible, which clinicians can use to assess whether dressing changes are needed.

[0063] The top dressing 102 is a covering layer used to cover the lower layer of the dressing, helping to seal the layer between the wound contact layer and the top dressing. The top dressing 102 can be a polyurethane layer. The top dressing can be coated with any suitable adhesive. Appropriately, the adhesive will be a pressure-sensitive adhesive, such as an acrylic adhesive or a silicone adhesive.

[0064] Therefore, the top membrane 102 helps ensure that the dressing remains breathable, that is, allows a certain proportion of the fluid absorbed in the dressing to evaporate through the outer surface of the dressing. In this way, some of the fluid contents of the exudate can drain from the dressing, reducing the volume of remaining exudate and increasing the time before the dressing becomes saturated. In addition, the top cover 102 helps ensure that the boundary area 110 of the dressing remains breathable, that is, allows the patient's normal skin sweat to evaporate through the dressing, which helps prevent or minimize skin maceration.

[0065] The outer layer of the dressing disclosed herein can be a continuous conformal film when present. The continuous water vapor transport conformal film outer layer of the wound dressing can be used to regulate moisture loss from the wound area beneath the dressing and can also act as a bacterial barrier, preventing bacteria on the outer surface of the dressing from penetrating into the wound area. A suitable continuous conformal film will have a water vapor transport rate of at least 300 g / m² / 24 h at 37.5°C with a relative humidity difference of 100% to 10%. Suitablely, it will be 300 to 5000 g / m² / 24 h, preferably 500 to 2000 g / m² / 24 h. This water vapor transport rate of the continuous film allows the wound beneath the dressing to heal under moist conditions without macerating the skin around the wound.

[0066] The laminated sheet of the present invention may include a superabsorbent layer 103 and a masking layer 105 as a deformable first layer and a top film 102 as a second layer, or an absorbent layer 104 as a deformable first layer and a wound contact layer 101 as a second layer, such as Figure 1 As shown.

[0067] This method can be used as follows Figures 2-7 The device shown is used to perform the operation. Figure 2This is a schematic diagram of an apparatus 200 for producing laminated material 201. The apparatus 200 includes a cutting device in the form of a carbide slicing blade on a roller 210, a transfer device in the form of a vacuum anvil 220, and a device for conveying a second layer in the form of a large-diameter assembly drum 230. The apparatus can take the form of a machine or a combination or series of machines arranged in a production line and suitable for mass production. Deformable material 240 is fed between the carbide slicing blade 210 and the vacuum anvil 220. The deformable foam material 240 travels at a first feed rate. The vacuum anvil 220 rotates at a constant rate, causing its surface to travel at substantially the same rate as the first feed rate. The vacuum anvil travels at a substantially constant rate. The carbide slicing blade 210 cuts the deformable foam material 240 into discrete portions 250, which are simultaneously transferred to the surface of the vacuum anvil 220. The second layer 260 travels around the large-diameter assembly drum 230 at a second feed rate, which is approximately twice the first feed rate. The large assembly drum travels at a substantially constant rate. The second layer 260 typically has a pressure-sensitive adhesive layer applied to its first surface 270. As the vacuum anvil 220 rotates, discrete portions 250 of the deformable first layer are transferred at regular, predetermined intervals to the adhesive-coated first surface 270 of the second layer. A closed-loop control system 290, including a detection device 291 in the form of a laser or vision detector, positions the leading edge of the discrete portions of the deformable material 250 on the first surface of the second layer 270, and an adjustment device 292 in the form of a servo motor adjusts the horizontal position of the large-diameter assembly drum 230 relative to the clamping point of the discrete portions of the deformable material 250 and the first surface of the second layer 270 to accurately position the discrete portions of the deformable material 250 onto the second layer 270.

[0068] Figure 3 This is a schematic diagram of equipment 300 used in a method for producing laminate 301 according to a first embodiment. This equipment is related to... Figure 2 The difference in the device is that the servo motor 392 adjusts the vertical position of the large-diameter assembly drum 330 relative to the clamping point of the discrete portion of the deformable material 350 and the first surface of the second layer 370.

[0069] Figure 4 This is a schematic diagram of another piece of equipment 400 used in the method for producing laminate 401 according to the first embodiment. This equipment is related to... Figure 2The difference in this device lies in the presence of a second transfer device, namely a large-diameter vacuum transfer roller 480, located between the vacuum anvil 420 and the large-diameter assembly drum 430. The large-diameter vacuum transfer roller 480 transfers discrete portions of the deformable material 450 from the vacuum anvil 420 to the second layer 460. The outer surface of the large-diameter vacuum transfer roller 480 travels at a rate equal to the feed rate of the second layer 460; that is, the large-diameter vacuum transfer roller 480 accelerates the discrete portions of the deformable material 450 from a first feed rate to a second feed rate. The large-diameter vacuum transfer roller travels at a substantially constant rate.

[0070] Figure 5 This is a schematic diagram of equipment 500 used in a method for producing laminate 501 according to a first embodiment. This equipment is related to... Figure 4 The difference in this device lies in that the transfer device includes a vacuum transfer belt 591 and a cam and follower 592 as a second transfer device. The vacuum transfer belt can travel at a substantially constant rate. The vacuum transfer belt can travel at a first feed rate. The cam and follower are driven by a servo motor. The cam and follower can be adjusted via an optional feedback loop. The vacuum transfer belt can apply a vacuum to discrete portions of the deformable material over its entire length, or the vacuum can be closed near the cam and follower to prevent stretching at the point where the discrete portions of the deformable material are applied to the second layer. Contact with the adhesive applied to the second layer pulls the discrete portions of the deformable material onto the second layer. The surface of the vacuum transfer belt can be textured.

[0071] Figure 6 This is a schematic diagram of equipment 600 used in a method for producing laminate 601 according to a first embodiment. This equipment is related to... Figure 2 The difference in the device is that a traction roller 631 with a cam and a follower 632 replaces the large-diameter assembly drum.

[0072] Figure 7 This is a schematic diagram of equipment 700 used in a method for producing a laminate 701 according to a first embodiment. This equipment is related to... Figure 4 The difference in the device is that the push rod conveyor 791 is the second transfer device and operates substantially at a second feed rate. The push rod conveyor can travel at a substantially constant rate. The suspended vacuum conveyor 792 transfers discrete portions of the deformable material 750 from the push rod conveyor 791 to the second layer 760, and moves the second layer 760 through the device using traction rollers 730. The push rod conveyor 791 produces the desired spacing of the discrete portions. In an alternative embodiment, the push rod conveyor can be replaced by a vacuum belt.

[0073] While this disclosure includes certain embodiments, examples, and applications, those skilled in the art will understand that this disclosure extends beyond the specific disclosed embodiments to other alternative embodiments or uses, as well as obvious modifications and equivalents thereof, including embodiments that do not provide all the features and advantages described herein. Therefore, the scope of this disclosure is not intended to be limited by the specific disclosure of preferred embodiments herein, but may be defined by the claims set forth herein or to be filed hereafter.

[0074] Conditional language, such as “can,” “may,” “possibly,” or “may,” unless explicitly stated otherwise or otherwise understood in the context in which they are used, is generally intended to express that certain embodiments include certain features, elements, or steps that are not included in other embodiments. Therefore, such conditional language is not generally intended to imply that one or more embodiments require features, elements, or steps in any way, or that one or more embodiments must include logic for determining whether such features, elements, or steps are included in or performed in any particular embodiment, with or without user input or prompting. The terms “comprising,” “including,” “having,” etc., are synonymous and used in an open-ended manner, and do not exclude additional elements, features, actions, operations, etc. Additionally, the term “or” is used in its inclusive sense (rather than in its proprietary sense) such that, when used, for example, to connect lists of elements, the term “or” means one, some, or all of the elements in the list. Furthermore, in addition to having its ordinary meaning, the term “each,” as used herein, can mean any subset of the set of elements to which the term “each” is applied.

[0075] Unless otherwise explicitly stated, union language such as the phrase “at least one of X, Y, and Z” is understood in context to generally indicate that an item, term, etc., can be X, Y, or Z. Therefore, such union language is not generally intended to imply that certain implementations require the presence of at least one of X, at least one of Y, and at least one of Z.

[0076] The degree language used herein, such as the terms “approximately,” “about,” “substantially,” and “basically,” refers to a value, quantity, or characteristic that is close to, yet still performs, the desired function or achieves the desired result. For example, the terms “approximately,” “about,” “substantially,” and “basically” can refer to a quantity that is less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the specified quantity. As another example, in some embodiments, the terms “substantially parallel” and “basically parallel” refer to a value, quantity, or characteristic that deviates from perfect parallelism by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degrees.

[0077] The terms "laminated body" and "laminated material" are used interchangeably.

[0078] The scope of this disclosure is not intended to be limited by the specific disclosure of preferred embodiments in this part or elsewhere in this specification, and may be defined by the claims set forth in this part or elsewhere in this specification or to be filed in the future. The language of the claims will be interpreted broadly based on the language used in the claims and is not limited to the examples described in this specification or during the examination of the application, which shall be interpreted as non-exclusive.

Claims

1. A continuous method for forming a laminate, wherein the laminate comprises a discrete deformable first layer having a first surface and a second surface and a substantially continuous second layer having a first surface and a second surface, wherein the method comprises supplying a substantially continuous layer of deformable material at a first feed rate and supplying a substantially continuous second layer at a second feed rate, wherein the second feed rate is greater than the first feed rate. The substantially continuous layer of the deformable material is cut into discrete portions; the discrete portions of the deformable first layer are transferred to a transfer device; The discrete portion of the deformable first layer is transferred from the transfer device to the first surface of the second layer at a predetermined position on the first surface of the second layer, such that the second surface of the deformable layer contacts the first surface of the second layer, wherein the method includes means of adjusting the predetermined position using a feedback loop including a detector device and an adjustment device.

2. The method according to claim 1, wherein the feedback loop is a closed feedback loop.

3. The method according to claim 1 or claim 2, wherein the adjusting device comprises, preferably, using a servo motor or a cam and a follower to vertically adjust the position of the second layer relative to the first layer.

4. The method according to claim 1 or claim 2, wherein the adjusting device comprises preferably using a servo motor, a cam and a follower, or a conveyor belt to horizontally adjust the position of the second layer relative to the first layer.

5. The method according to claim 4, wherein the conveyor belt is a pusher belt, a vacuum belt, or a combination thereof.

6. The method according to any of the preceding claims, wherein the transfer device travels at substantially the same rate as the substantially continuous layer of the deformable material.

7. The method of claim 1, wherein the transfer device travels at a substantially constant rate.

8. The method according to any of the preceding claims, wherein the transfer device is a vacuum roller.

9. The method according to any of the preceding claims, wherein the cutting device is a blade attached to the roller, preferably wherein the blade is a carbide slicing blade.

10. The method of claim 9, wherein the transfer device serves as the anvil of the cutting device.

11. The method according to any of the preceding claims, wherein the method further comprises a second transfer device.

12. The method according to claim 11, wherein the second transfer device is a transfer roller or a vacuum conveyor.

13. The method of claim 11 or claim 12, wherein the second transfer device accelerates the feed rate of the discrete portion of the deformable material to substantially the second feed rate.

14. The method according to any of the preceding claims, wherein the first layer is an absorbent layer, preferably a foam layer.

15. The method according to any of the preceding claims, wherein the second layer is a substantially non-deformable layer, preferably the second layer comprising a polymer film.

16. The method according to any of the preceding claims, wherein the second layer has an adhesive layer applied to the first surface of the second layer.

17. The method according to any of the preceding claims, wherein the laminate is suitable for wound dressings.

18. A laminate capable of being produced by the method according to any of the preceding claims.

19. A wound dressing comprising the laminate according to claim 18.

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