Method for manufacturing wound dressing

Abstract

The present disclosure generally comprises the following steps: a) providing an absorbent laminate web (101), said absorbent laminate web (101) comprising at least a first layer (101a) and a second layer (101b); b) providing a plurality of distinct cuts (102) in the absorbent laminate web (101) by feeding the absorbent laminate web (101) through a rotary cutting tool (103) including a punch roll (104) and an opposing anvil roll (105), the punch roll (104) having an outer surface including a plurality of distinct cutting blade structures (106), the anvil roll (105) having a flat outer surface, and the punch roll (104) and the anvil roll (105) the absorbent laminate web (101) is fed to the rotary cutting tool (103) such that the anvil roll (105) and the punch roll (104) rotate in opposite directions, with the second layer (101b) facing the outer surface of the anvil roll (105) and the first layer (101a) facing the outer surface of the punch roll (104), the rotary cutting tool (103) being configured to make the plurality of discrete cuts (102) in the first layer (101a) while leaving the second layer (101b) intact; c) cutting the absorbent laminate web (101) containing the plurality of separate cuts (102) into a plurality of separate absorbent laminate substrates (107); d) placing the separate absorbent laminate substrate (107) on the backing layer web (108) so that the first layer (101a) of the absorbent laminate substrate (107) faces the backing layer web (108); e) applying an adhesive skin contact layer (109) onto the second layer (101b) of each of the absorbent laminate substrates (107), thereby providing an assembled wound dressing web; f) separating individual wound dressings from the wound dressing web assembly; The present invention relates to a method for producing a wound dressing comprising the steps of: The present disclosure also relates to wound dressings formed according to the present methods.

Description

[Technical Field]

[0001] The present disclosure generally relates to a method for manufacturing a wound dressing, which may be performed at high speed in a continuous manner and provides a wound dressing with improved flexibility. The present disclosure also relates to a wound dressing formed according to the method. [Background technology]

[0002] Adhesive wound dressings are frequently used in wound care, both to treat wounds and scars and to prevent them from occurring in the first place.

[0003] Various characteristics are generally desired for wound dressings. For example, wound dressings should be able to handle large amounts of wound exudate. To that end, they often contain superabsorbent materials, such as superabsorbent polymer particles or superabsorbent fibers. However, when superabsorbent materials are present in wound dressings, it is important to prevent such materials from coming into direct contact with the patient's wound. Leakage of superabsorbent materials into the wound can be harmful to the patient's wound and skin. Skin rashes and skin inflammation can occur, impairing the wound healing process.

[0004] Furthermore, the wearability or wear time of the dressing is important. High performance wound dressings utilized in hospitals and care facilities are typically expensive to manufacture. Consequently, changing the dressing too frequently entails high costs.

[0005] To improve the wear time of the dressing, the dressing should preferably be flexible so that it can adapt to the patient's movements and stay on the skin as the patient moves.

[0006] The flexibility of a wound dressing can be increased by providing cuts or slits in the wound pad of the dressing. However, this can be associated with challenges during manufacturing. This is particularly true when the wound pad includes multiple layers and when the wound pad includes superabsorbent material. Wound pads that include cuts may increase the risk of the superabsorbent material interfering with the patient's wound or skin. Cuts or slits in the wound pad may also increase the risk of exudate backflow, in other words, wound exudate may flow back toward the wound site during use.

[0007] Generally, the manufacture of wound dressings involves a series of steps that create various continuous webs of material and separate individual wound dressings from these assemblies. A significant amount of waste is typically generated throughout the stages of the process.

[0008] There is a need for improved processes for manufacturing wound dressings in general, particularly where cuts or slits are to be included in the wound pad. Such processes should be efficient, economical, and capable of high speed production. Furthermore, the processes should provide for the production of wound dressings with improved donning times as well as improved liquid handling properties. Summary of the Invention [Problem to be solved by the invention]

[0009] In view of the above-mentioned problems, it is an object of the present disclosure to provide an improved method for manufacturing a wound dressing. [Means for solving the problem]

[0010] According to a first aspect, there is provided a method of manufacturing a wound dressing, the method comprising: a) providing an absorbent laminate web, said absorbent laminate web comprising at least a first layer and a second layer; b) providing a plurality of separate cuts in the absorbent laminate web by feeding the absorbent laminate web into a rotary cutting tool including a punch roll and an opposing anvil roll, wherein the punch roll has an outer surface including a plurality of separate cutting blade structures, the anvil roll has a flat outer surface, the punch roll and the anvil roll rotate in opposite directions, the absorbent laminate web is fed into the rotary cutting tool with the second layer facing the outer surface of the anvil roll and the first layer facing the outer surface of the punch roll, and the rotary cutting tool provides the plurality of separate cuts in the first layer but leaves the second layer intact; c) cutting the absorbent laminate web containing the plurality of discrete cuts into a plurality of discrete absorbent laminate substrates; d) placing the absorbent laminate substrate on a back layer web so that the first layer of the absorbent laminate substrate faces the back layer web; e) applying an adhesive skin contact layer onto the second layer of each of the absorbent laminate substrates, thereby providing an assembled wound dressing web; f) separating individual wound dressings from the wound dressing web assembly; Includes.

[0011] The method according to the present disclosure can be performed rapidly, continuously, and generates less waste during processing.

[0012] The multiple separate cuts in the absorbent laminate web do not create waste material and do not require material to be removed during this step (step b).

[0013] Furthermore, by cutting the absorbent laminate web into a plurality of separate absorbent laminate substrates (step c) before attachment of the backing layer and adhesive skin contact layer, less raw material waste is produced compared to separating the individual wound dressings after the absorbent laminate web has been attached to the backing layer and adhesive skin contact layer.

[0014] In the disclosed process, multiple discrete cuts are made in the first layer to make the wound pad and the entire dressing more flexible. In this regard, a more flexible dressing is provided that can conform to the patient's movements, thereby improving the wear time of the dressing.

[0015] The second layer of the absorbent laminate web is designed to be placed in contact with the adhesive wound contact layer. This layer is unslit. This is beneficial because it prevents potential superabsorbent materials from reaching the wound and the surrounding skin. In this regard, the second layer functions as a filter layer. Furthermore, the intact second layer prevents backflow of wound exudate. This can be particularly noticeable when slits are provided in the absorbent laminate, i.e., the wound pad.

[0016] Making multiple separate cuts after the absorbent laminate is installed also saves considerable time compared to the conventional process of making cuts in one layer and then laminating such layer with an intact second layer.

[0017] In an exemplary embodiment, the separate cutting blades on the outer surface of the punch roll are positioned in close proximity to, but not in direct contact with, the outer surface of the anvil roll.

[0018] Thus, the notches will only be provided in the layer that is placed in contact with the outer surface of the punch roll.

[0019] If the absorbent laminate web comprises multiple layers, the method may be adjusted to provide cuts in one or some of these layers, but leave the second layer intact, i.e., without cuts.

[0020] In an exemplary embodiment, a first layer of the absorbent laminate web comprises a superabsorbent material and a second layer of the absorbent laminate web is free of superabsorbent material.

[0021] It is preferred that the superabsorbent material not be present in close proximity to the wound, as leakage of the superabsorbent material can have detrimental effects on the patient's wound and skin. Thus, when the adhesive skin contact layer is perforated or provided as a coating on a second layer, the risk of leakage of the superabsorbent material into the wound or skin site is eliminated.

[0022] The second layer is not limited to any particular material.

[0023] However, in an exemplary embodiment, the second layer comprises a foam or a nonwoven.

[0024] For example, the second layer may be a polyurethane foam layer or a nonwoven fabric layer.

[0025] The polyurethane foam layer has the ability to absorb and handle large amounts of fluid exuded from the wound site, while the nonwoven fabric layer has the ability to diffuse and distribute the wound exudate before it enters the remaining layers of the absorbent laminate, i.e., the wound pad, thus improving the liquid handling properties of the final wound dressing.

[0026] In an exemplary embodiment, the adhesive skin contact layer comprises a polymer film a having an adhesive silicone gel coating.

[0027] The adhesive silicone gel coating is configured to contact the user's skin. The polymer film provides stability to the adhesive skin contact layer. The adhesive skin contact layer may be formed as a web in the process and attached to the remaining components of the wound dressing. The polymer film provides stability to the adhesive skin contact layer web during processing.

[0028] The adhesive silicone gel may be pre-coated onto a polymer film and then fed into the process line as an adhesive skin contact layer web.

[0029] Typically, the adhesive skin contact layer comprises a plurality of perforations.

[0030] The perforations allow exudate to enter the wound dressing so that it can be distributed within the wound dressing and then evaporated from the backing layer.

[0031] When the adhesive skin contact layer comprises a polymeric film and an adhesive silicone gel coating, the perforations extend through both the polymeric film and the adhesive silicone gel coating.

[0032] The adhesive skin contact layer is preferably pre-perforated before application onto the absorbent laminate and before entering the process line, which further saves time during manufacturing.

[0033] In step d) of the process, a plurality of separate absorbent laminate substrates can be placed on the backing layer web at predetermined distances from each other.

[0034] The predetermined distance preferably sets the size of a border provided around the outline of each of the absorbent laminate substrates.

[0035] Arrangement of the absorbent laminate substrates at predetermined distances from one another can be achieved by adjusting the line speed of the backing layer web with the line speed at which the individual absorbent laminate substrates are conveyed onto the backing layer web, which may be greater than the speed at which the absorbent laminate substrates are applied onto the backing layer web.

[0036] Step e) of applying the adhesive skin contact layer may include placing an adhesive skin contact layer web on the second layer of each of the separate absorbent laminate substrates, the adhesive skin contact layer web being coextensive with the backing layer web.

[0037] Thus, the interface formed by both the adhesive skin contact layer and the backing layer can be completed, which improves the wearability of the final wound dressing.

[0038] In step f) of the process, individual wound dressings may be cut so that the border formed from the backing layer and the adhesive skin contact layer is provided around the outline of each individual absorbent laminate substrate.

[0039] Preferably, the method is a continuous, automated method.

[0040] Thus, the method can proceed without interruption and no manual steps are required.

[0041] In an exemplary embodiment, the absorbent laminate web has a transverse (x) extension and a longitudinal (y) extension, the transverse (x) extension corresponds to the machine direction (MD), and the tensile strength of the absorbent laminate web is higher in the transverse (x) direction than in the longitudinal (y) direction.

[0042] This is beneficial in providing stability to the process. Furthermore, the step of separating the absorbent laminate substrate from the absorbent laminate web is significantly simplified. If the absorbent laminate web is too flexible in all directions during this step, the peripheral edge of the absorbent laminate substrate may break during cutting.

[0043] The die cut roll has an outer surface including a plurality of discrete cutting blade structures, each having a shape corresponding to a respective one of a plurality of discrete cuts provided in the absorbent laminate web.

[0044] In an exemplary embodiment, each of the plurality of separate cutting blade structures has a shape selected from an arcuate shape such as a cross, a star, a Y, or a C-shape.

[0045] Therefore, the first layer of absorbent laminate is provided with multiple cuts at an angle to both the machine and cross directions, which makes the absorbent laminate substrate for forming the wound pad in the final wound dressing more flexible, allowing the final wound dressing to conform to the patient's movements and thereby increasing the wear time.

[0046] In an exemplary embodiment, the absorbent laminate web can include at least a third layer, the third layer being disposed on top of the first layer or between the first and second layers, the third layer also comprising a plurality of separate cuts.

[0047] The absorbent laminate may include various additional layers, which may also include multiple, separate cuts to improve overall flexibility. However, it is important that the second layer remains intact and free of cuts.

[0048] According to another aspect, there is provided a wound dressing manufactured according to the aforementioned method, the wound dressing comprising a backing layer, an adhesive skin contact layer, and an absorbent laminate substrate comprising at least a first layer and a second layer, the first layer comprising a superabsorbent material and having a plurality of separate incisions therein, and the second layer positioned in contact with the adhesive skin contact layer and being free of the superabsorbent material and the separate incisions.

[0049] Further features and advantages of the present disclosure will become apparent upon review of the appended claims and the following description. Those skilled in the art will appreciate that different features of the present disclosure can be combined to create embodiments other than those described below without departing from the scope of the disclosure. [Brief explanation of the drawings]

[0050] The various aspects of the present disclosure, including its particular features and advantages, will be readily understood from the following detailed description and the accompanying drawings.

[0051] [Figure 1] FIG. 1 illustrates a schematic diagram of a method for manufacturing a wound dressing according to an exemplary embodiment of the present disclosure. [Figure 2] FIG. 2 shows a schematic representation of a coating that can be formed by the method shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0052] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which presently preferred embodiments of the disclosure are shown. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for completeness and completeness so as to fully convey the scope of the disclosure to those skilled in the art. Like reference numerals refer to like elements throughout.

[0053] Referring to FIG. 1, a method for manufacturing a wound dressing 100 according to an exemplary embodiment of the present disclosure is conceptually illustrated.

[0054] The method comprises: a) providing an absorbent laminate web 101, the absorbent laminate web 101 comprising at least a first layer 101a and a second layer 101b; b) making a plurality of separate cuts 102 in the absorbent laminate web 101 by feeding the absorbent laminate web 101 through a rotary cutting tool 103 including a punch roll 104 and an opposing anvil roll 105, wherein the punch roll 104 has an outer surface including a plurality of separate cutting blade structures 106, the anvil roll 105 has a flat outer surface, the punch roll 104 and the anvil roll 105 rotate in opposite directions, the absorbent laminate web 101 is fed into the rotary cutting tool 103 such that the second layer 101b faces the outer surface of the anvil roll 105 and the first layer 101a faces the outer surface of the punch roll 104, and the rotary cutting tool 103 is configured to make the plurality of separate cuts 102 in the first layer 101a but leave the second layer 101b intact; c) separating the absorbent laminate web 101 containing the plurality of separate cuts 102 into a plurality of separate absorbent laminate substrates 107; d) placing a separate absorbent laminate substrate 107 onto the backing layer web 108 such that the first layer 101a of the absorbent laminate substrate 107 faces the backing layer web 108; e) applying an adhesive skin contact layer 109 onto the second layer 101b of each of the absorbent laminate substrates 107, thereby forming an assembled wound dressing web; f) separating individual wound dressings from the wound dressing web assembly; Includes:

[0055] The absorbent laminate web 101 may be provided by means known to those skilled in the art (step a).

[0056] For example, the first laminate layer may be attached to the second laminate layer by adhesive, heat, welding, etc. In an exemplary embodiment, the first and second layers of the absorbent laminate web are attached by a hot melt adhesive.

[0057] In the context of this disclosure, the absorbent laminate web 101 is a pre-fabricated absorbent laminate web, so that the various layers of the absorbent laminate web have been fabricated prior to step a) of the present process.

[0058] As shown in Figure 1, in step b) of the process, absorbent laminate web 101 is fed to a rotary cutting tool 103. Rotary cutting tool 103 includes a punch roll 104 and an opposing anvil roll 105.

[0059] The punch roll 104 and the anvil roll 105 rotate in opposite directions. The outer surface of the punch roll 104 faces the outer surface of the anvil roll 105.

[0060] A plurality of discrete cutting blade structures 106 on the outer surface of the punch roll 104 define the shape of the discrete cuts made in the first layer 101 a of the absorbent laminate web 101 .

[0061] As used herein, the term "separate cutting blade structures" means that the cutting blade structures are positioned separate and isolated from adjacent cutting blade structures. The separate cutting blade structures are intended to cut, i.e., slit, the absorbent laminate web. Each cutting blade structure typically has a small width. The width of each cutting blade structure can be 0.1 mm to 1 mm.

[0062] The distance between adjacent cutting blade structures may be from 1 mm to 15 mm, for example from 2 mm to 10 mm.

[0063] In this way, sufficient area of ​​absorbent laminate material is provided between each separate incision. Therefore, the absorbent laminate web can still absorb and handle wound exudate in an appropriate manner. Furthermore, the risk of the incised absorbent laminate web rupturing or tearing is minimized. The provision of incisions (as compared to, for example, openings or channels) also minimizes the risk of exudate backflow toward the wound site.

[0064] The cutting blade structures are not limited to a particular shape. Preferably, each cutting blade structure has a shape that provides a cut at an angle relative to the machine direction (MD) and cross direction (CD) of the absorbent laminate substrate.

[0065] The term "separate cuts" means that the cuts are spaced apart and isolated from adjacent cuts. Separate cuts represent slits from which as little material as possible is removed during cutting. Preferably, no material is removed.

[0066] The shape of each separate notch corresponds to the shape of each separate cutting blade structure.

[0067] The separate cuts extend completely through the first layer. The second layer remains "intact," meaning that the separate cuts do not extend completely through the second layer.

[0068] The separate cutting blade structures extend radially from the outer surface of the punch roll 104. The maximum radial extension or height of each cutting blade structure can vary depending on the thickness of the absorbent laminate web and the thickness of the individual layers contained therein. The height can be adjusted depending on the characteristics of the second layer of the absorbent laminate web. This layer should not contain any notches.

[0069] The cross-sectional area of ​​the punch roll 104 in the areas where the individual cutting blade structures 106 are located is greater than the cross-sectional area of ​​the punch roll 104 in the areas between the cutting blade structures 106 .

[0070] The anvil roll 105 has a flat outer surface. Therefore, the anvil roll 105 has a uniform outer surface. In the region of the anvil roll 105 through which the absorbent laminate web is transported, the cross-sectional area of ​​the anvil roll is the same. As a result, there is no variation in the diameter of the anvil roll 105 as a whole.

[0071] The second layer 101b faces the outer surface of the anvil roll 105 and is disposed so as to be in contact therewith. The first layer 101a faces the outer surface of the punch roll 104 and is disposed so as to be in contact therewith.

[0072] The rotary cutting tool 103 is configured to make a plurality of discrete cuts 102 in the first layer 101a, but leave the second layer 101b intact.

[0073] To accomplish this, separate cutting blades 106 may be positioned in close proximity to, but not in direct contact with, the outer surface of the anvil roll 105 .

[0074] The distance between the outermost edge 113 of the cutting blade structure 106 and the outer surface of the anvil roll 104 can be adjusted depending on the thickness of the second layer 101 b of the absorbent laminate web 101 .

[0075] The outermost edge of the cutting blade structure defines the maximum radial extension, or height, of the cutting blade structure.

[0076] The distance between the outermost edge of the cutting blade structure and the outer surface of the anvil roll may be from 0.02 mm to 1.0 mm, for example from 0.03 mm to 0.8 mm.

[0077] The distance can be adjusted by any means known to those skilled in the art.

[0078] 1, the distance between the cutting blade structures 106 and the outer surface of the anvil roll 105 can be adjusted by providing raised sides 112 on the punch roll 104. Thus, the diameter of the sides 112 is greater than the maximum diameter of the punch roll 104 in the area where the individual blade structures 106 are located. Thus, there will be a distance of height h1 between the sides 112 and the outermost edge 113 of the cutting blade structures 106. Height h1 can be adjusted depending on the thickness of the second layer 101b of the absorbent laminate web 101.

[0079] It is also contemplated that the distance between the outermost edge of the cutting blade structure and the outer surface of the anvil roll may be adjusted in a different manner. For example, the anvil roll may be an adjustable anvil roll. The anvil roll may have three separate sections, such as a first side section, a second side section, and a third central section disposed between the first and second side sections. The third central section may be movable relative to the sides and may be lowerable. Thus, the height h1 may be adjusted in this alternative manner.

[0080] Step c) of cutting the absorbent laminate web 101 containing the plurality of separate cuts 102 into a plurality of separate absorbent laminate substrates 107 is not limited to any particular method or technique.

[0081] As shown in FIG. 1, step c) may be performed by feeding an absorbent laminate web 101 containing a plurality of separate cuts 102 into a profile cutting tool 114 .

[0082] The profile cutting tool 114 is configured to cut through all layers of the absorbent laminate web 101 .

[0083] The profile cutting tool 114 may comprise a roll 115 having an outer surface that includes a cutting blade profile 116 that corresponds to the shape of the absorbent laminate substrate 107 to be formed.

[0084] Although the shape of the absorbent laminate substrate 107 is shown as a square in Figure 1, the absorbent laminate substrate is not limited to such a shape. For example, the shape of the absorbent laminate substrate 107 may be rectangular, oval, circular, or any other conceivable shape. The shape of the absorbent laminate substrate 107 may be adjusted by a contour cutting tool 114.

[0085] Step d) of placing the separate laminate substrate 107 on the backing layer web 108 so that the first layer 101a of the absorbent laminate substrate 107 faces the backing layer web 108 can be carried out by any suitable technique known to those skilled in the art.

[0086] For example, as shown in Figure 1, after the absorbent laminate web 101 is cut by a contour cutting tool 114, the individual absorbent laminate substrates 107 can be placed on a conveyor belt 117. The absorbent laminate substrates 107 may then be placed on a conveyor roll 118. A vacuum (indicated by the arrows in Figure 1) can be applied to ensure that the individual absorbent laminate substrates 107 remain on the surface of the conveyor roll 118.

[0087] The absorbent laminate substrate is placed on the backing layer web 108 such that the first layer 101a of the absorbent laminate substrate 107 faces the backing layer web 108. The first layer 101a may be placed in contact with the backing layer web 108 as shown in FIG.

[0088] The present disclosure is in no way limited to the particular conveyor belts and rolls shown in FIG. 1, and any means for conveying various webs and materials is contemplated.

[0089] Step e) of applying an adhesive skin contact layer onto the second layer 101b of the absorbent laminate substrate 107 can be provided by means known to those skilled in the art.

[0090] For example, the adhesive skin contact layer may be provided as a coating directly on the absorbent laminate substrate 107 and / or backing layer web 108 .

[0091] Alternatively, the adhesive skin contact layer is provided as an adhesive skin contact layer web and applied to the second layer 101 b of the absorbent laminate 101 .

[0092] Step f) of separating the individual wound dressings from the wound dressing web may be carried out by any means known to those skilled in the art.

[0093] The various layers of the wound dressing may be attached to one another by conventional means such as adhesives.

[0094] The first layer 101a of the absorbent laminate web 101 may include a superabsorbent material, and the second layer 101b of the absorbent laminate web 101 preferably does not include a superabsorbent material.

[0095] As used herein, the term "superabsorbent material" refers to a material containing superabsorbent polymers (SAPs). Superabsorbent polymers can absorb more than 100 times their own weight in aqueous fluids. Superabsorbent polymers are composed of water-swellable and water-insoluble polymers that can absorb large amounts of fluid upon forming a hydrogel. Superabsorbent polymers for use in accordance with the present disclosure can be inorganic or organic cross-linked hydrophilic polymers, such as polyvinyl alcohol, polyethylene oxide, cross-linked polyacrylates, and the like. Typically, superabsorbents (SAPs) contain sodium acrylate. SAP materials may be in the form of particles, fibers, flakes, powders, and the like. Preferably, the SAP material is in the form of superabsorbent polymer (SAP) particles or fibers (SAFs).

[0096] The second layer 101b of the absorbent laminate web 101 is a continuous layer, is unscored, and is a superabsorbent material.

[0097] The second layer 101b of the absorbent laminate web 101 represents the layer 107b of the absorbent laminate substrate 107 that is placed in contact with the adhesive skin contact layer 109 in the wound dressing 100 formed by the method of the present disclosure (see Figure 2).

[0098] In Figure 2, the various absorbent laminate layers of the absorbent laminate substrate 107 are designated 107a through 107c. The first layer 107a of the absorbent laminate substrate 107 is formed from the first layer 101a of the absorbent laminate web 101. The second layer 107b of the absorbent laminate substrate 107 is formed from the second layer 101b of the absorbent laminate web 101. The dressing of Figure 2 also includes a third layer 107c disposed between the first layer 107a and the second layer 107b of the absorbent laminate substrate 107. The third layer 107c may be formed from a third layer disposed between the first layer 101a and the second layer 101b of the absorbent laminate web 101.

[0099] Thus, the features and characteristics described in connection with layers 101a to 101c of absorbent laminate web 101 apply to absorbent laminate substrate layers 107a to 107c.

[0100] The absence of superabsorbent material in the second layer 101b eliminates the risk of SAP leakage into the wound site and onto the skin during use of the final wound dressing, which could potentially occur if the adhesive skin contact layer were to be perforated.

[0101] The second layer 101b may comprise a foam or a nonwoven.

[0102] The foam is preferably hydrophilic and absorbent. Absorbent foams have the ability to efficiently absorb wound exudate and transport such exudate away from the wound site.

[0103] Preferably, the foam is a hydrophilic porous polyurethane foam. The polyurethane foam may contain pores having an average pore size in the range of 30 μm to 1000 μm.

[0104] The second layer 101b may alternatively be a nonwoven layer. A nonwoven layer has the ability to efficiently distribute fluid so that wound exudate is spread over a larger surface area. This is beneficial both when exudate is transported away from the wound site and when exudate is transported back toward the wound site.

[0105] The nonwoven layer may comprise a meltblown, spunbond, or spunlace nonwoven. Examples of polymers suitable for use in the nonwoven are homopolymers and copolymers of polyethylene, polyester, polypropylene, and other polyolefins. For example, a nonwoven web comprising thermoplastic fibers of polypropylene and polyethylene fibers or a mixture thereof can be used. The web can have a high content of thermoplastic fibers, and can contain at least 50%, for example at least 70%. The nonwoven may be a blend of polyester and viscose, for example in a 70:30 ratio. The basis weight of the nonwoven may be from 10 to 80 g / m 2 , e.g., 20 to 50 g / m 2 The liquid spreading layer may be a spunbond-meltblown or spunbond-meltblown-spunbond (SMS) web.

[0106] The adhesive skin contact layer 109 may include a polymer film with an adhesive silicone gel coating.

[0107] The polymer film provides stability to the adhesive skin contact layer 109. The adhesive skin contact layer is preferably pre-fabricated so that it can be provided in the process and applied to the absorbent laminate substrate 107 as an adhesive skin contact layer web.

[0108] The polymer film is preferably a breathable film. The polymer film may comprise polyethylene, polyamide, or polyurethane. Preferably, the polymer film comprises polyurethane. The thickness of the polymer film may be 15 to 100 μm, for example, 20 to 80 μm, preferably 20 to 50 μm.

[0109] Examples of silicone gels suitable for use in adhesive silicone gel coatings include two-component RTV systems such as Q72218 (Dow Corning) and SilGel 612 (Wacker Chemie AG), as described herein, and NuSil silicone elastomers. In embodiments of the present invention, the adhesive can include a soft silicone gel having a flexibility (penetration) of 8 to 22 mm, e.g., 12 to 17 mm, as measured by a method based on ASTM D 937 and DIN 51580, as described in European Patent Application No. 14194054.4. The thickness of the silicone gel layer is typically at least 20 μm. The thickness of the silicone gel layer can be 100 to 200 μm.

[0110] Preferably, the adhesive skin contact layer 109 includes a plurality of perforations 110 .

[0111] The perforations extend through the entire adhesive skin contact layer, ie, through both the polymer film and the adhesive silicone gel coating (if present).

[0112] As shown in Figure 2, the perforations may be provided in at least the area of ​​the adhesive skin contact layer 109, i.e., the wound pad, that underlies the absorbent laminate substrate 107. In the embodiment disclosed in Figure 2, the area of ​​the adhesive skin contact layer 109 that forms part of the interface portion 111 is free of perforations.

[0113] Alternatively, the perforations are provided over the entire surface of the adhesive skin contact layer 109 .

[0114] As shown in FIG. 1, in step d), a plurality of separate absorbent laminate substrates 107 may be placed on the backing layer web 108 at a predetermined distance from each other.

[0115] The predetermined distance may vary depending on the size of the wound dressing border, for example the predetermined distance may be 5 to 60 mm, such as 10 to 40 mm, so that a border of sufficient size is achieved.

[0116] The placement of the absorbent laminate substrates at a predetermined distance from each other may be adjusted by the line speed of the backing layer web 108, i.e., the speed at which the backing layer web 108 is transported. The line speed of the backing layer web 108 may be faster than the speed at which the absorbent laminate substrate 107 is transported. In FIG. 1, the speed of the absorbent laminate substrate 107 may be adjusted by the conveyor belt 117, but the process is not limited to this. In embodiments, the line speed of the absorbent laminate web 101 may be slower than the speed of the backing layer web 108.

[0117] Step e) of applying the adhesive skin contact layer 109 may include placing an adhesive skin contact layer web on the second layer 101b of each of the separate absorbent laminate substrates 107, where the adhesive skin contact layer web is coextensive with the backing layer web 108 (not shown in FIG. 1).

[0118] The adhesive skin contact web and the backing layer web 108 can be coextensive in length and width. The adhesive skin contact web and the backing layer web 108 may have the same surface area.

[0119] In step f), the individual wound dressings may be cut so that the border formed from the backing layer and the adhesive skin contact layer 109 is provided around the outline of each of the separate absorbent laminate substrates 107.

[0120] Thus, the backing layer of the final wound dressing will have the same width and length as the adhesive skin contact layer.

[0121] Thus, as shown in Figure 2, both the backing layer 108 and the adhesive skin contact layer 109 form part of the border 111 of the final wound dressing.

[0122] The border 111 improves adhesion to the patient's skin.

[0123] Preferably, the method is a continuous, automated method.

[0124] Therefore, the method can be performed quickly and without any interruptions or manual steps.

[0125] The absorbent laminate web 101 may have a transverse (x) extension and a longitudinal (y) extension, the transverse (x) extension corresponding to the machine direction (MD), and the tensile strength of the absorbent laminate web 101 is higher in the transverse (x) direction than in the longitudinal (y) direction.

[0126] This is beneficial from the standpoint of processing stability. Furthermore, when the absorbent laminate web 101 enters the profile cutting tool 114, the peripheral edge of the absorbent laminate substrate 107 is prevented from being broken or torn during cutting.

[0127] The separate cutting blade structures 106 are not limited to any particular shape, so long as they are configured to create cuts in the absorbent laminate web that are not apertures or larger holes.

[0128] Preferably, each of the plurality of discrete cutting blade structures 106 of the punch roll 104 has a shape selected from an arcuate shape such as a cross, a star, a Y, or a C-shape.

[0129] These shapes provide cuts in the absorbent laminate web and increase the overall flexibility of the final wound dressing.

[0130] In FIG. 1, a C-shaped cutting blade structure 106 is shown.

[0131] The absorbent laminate web 101 can include at least a third layer, which is disposed on top of the first layer 101a or between the first layer 101a and the second layer 101b, and which also includes a plurality of separate incisions 102.

[0132] The third layer of the absorbent laminate web may be a liquid transport layer, a liquid distribution layer and / or a liquid absorption layer.

[0133] FIG. 2 shows a wound dressing comprising an absorbent laminate substrate 107 having three laminate layers (107a to 107c).

[0134] The wound dressing 100 comprises a backing layer 108, an adhesive skin contact layer 109, and an absorbent laminate substrate 107 comprising at least a first layer 107a and a second layer 107b, wherein the first layer 107a comprises a superabsorbent material and is provided with a plurality of separate incisions 102, and the second layer 107b is positioned in contact with the adhesive skin contact layer 109 and is free of the superabsorbent material and the separate incisions 102.

[0135] 2, a third layer, designated 107c, is disposed between the first layer 107a and the second layer 107b. The third layer 107c includes a plurality of separate cuts 102, which improves the flexibility of the absorbent laminate substrate 107 and the dressing.

[0136] The second layer 107b is placed in contact with the adhesive skin contact layer 109. This layer is intact and is beneficial in preventing backflow of exudate and preventing leakage of the superabsorbent material into the wound site.

[0137] The dressing 100 may include additional layers and is by no means limited to the structure shown in FIG.

[0138] In FIG. 2, the adhesive skin contact layer 109 includes a plurality of perforations 110 in the area underlying the absorbent pad, but is free of openings in the area forming the border portion 111 .

[0139] The adhesive skin contact layer 109 is positioned to receive bodily fluids, such as wound exudate from the wound, while the absorbent laminate substrate 107 acts as a wound pad and is configured to absorb the wound exudate and transport it away from the wound by evaporating it from the top of the dressing, i.e., through the backing layer 108.

[0140] With respect to the dressing shown in FIG. 2, the first layer 107a is a layer comprising a superabsorbent material, preferably superabsorbent fiber (SAF), the second layer 107b can be an absorbent foam layer, and the third layer can be a nonwoven fabric layer.

[0141] Alternatively, the first layer 107a may be a tissue layer, the second layer 107b may be a nonwoven layer, and the third layer 107c may be a layer containing superabsorbent material. It is also contemplated that the absorbent laminate may include two layers. Thus, the first layer 107a may be a layer containing superabsorbent particles or fibers, and the second layer 107b may be a nonwoven layer.

[0142] The terms, definitions, and embodiments of all aspects of this disclosure apply mutatis mutandis to other aspects of this disclosure.

[0143] Although the present disclosure has been described with reference to specific exemplary embodiments thereof, many different alterations, modifications and the like will become apparent to those skilled in the art.

[0144] Variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the present disclosure, from a study of the drawings, the disclosure, and the appended claims. Moreover, in the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

Claims

1. 1. A method for manufacturing a wound dressing, comprising: a) providing an absorbent laminate web (101), said absorbent laminate web (101) comprising at least a first layer (101a) and a second layer (101b); b) providing a plurality of distinct cuts (102) in the absorbent laminate web (101) by feeding the absorbent laminate web (101) to a rotary cutting tool (103) including a punch roll (104) and an opposing anvil roll (105), wherein the punch roll (104) and the anvil roll (105) rotate in opposite directions, the absorbent laminate web (101) is provided to the rotary cutting tool (103) with the second layer (101b) facing the outer surface of the anvil roll (105) and the first layer (101a) facing the outer surface of the punch roll (104), and the rotary cutting tool (103) is configured to provide the plurality of distinct cuts (102) in the first layer (101a), while leaving the second layer (101b) intact; c) cutting said absorbent laminate web (101) containing said plurality of separate cuts (102) into a plurality of separate absorbent laminate substrates (107); d) placing said separate absorbent laminate substrate (107) on said backing layer web (108) so that said first layer (101a) of said absorbent laminate substrate (107) faces said backing layer web (108); e) applying an adhesive skin contact layer (109) onto the second layer (101b) of each of the absorbent laminate substrates (107), thereby providing an assembled wound dressing web; f) separating individual wound dressings from the wound dressing web assembly; A method for producing a wound dressing comprising:

2. 2. The method of claim 1, wherein the individual cutting blades (106) on the outer surface of the punch roll (104) are positioned adjacent to, but not directly contacting, the outer surface of the anvil roll (105).

3. 3. The method of claim 1 or 2, wherein the first layer (101a) of the absorbent laminate web (101) comprises a superabsorbent material and the second layer (101b) of the absorbent laminate web (101) does not comprise a superabsorbent material.

4. The method of any one of claims 1 to 3, wherein the second layer (101b) comprises a foam or a nonwoven.

5. 5. The method of any one of claims 1 to 4, wherein the adhesive skin contact layer (109) comprises a polymer film with an adhesive silicone gel coating.

6. The method of any one of claims 1 to 5, wherein the adhesive skin contact layer (109) comprises a plurality of perforations (110).

7. 7. The method according to claim 1, wherein in step d), the plurality of separate absorbent laminate substrates (107) are arranged on the backing layer web (108) at a predetermined distance from each other.

8. 8. The method of claim 1, wherein the step e) of applying an adhesive skin contact layer (109) comprises placing an adhesive skin contact layer web on the second layer (101b) of each of the separate absorbent laminate substrates (107), the adhesive skin contact layer web being coextensive with the backing layer web (108).

9. 9. The method according to claim 1, wherein in step f), the individual wound dressings are separated so that a boundary portion (111) formed from the backing layer and the adhesive skin contact layer (109) is provided around the outer contour of each of the separate absorbent laminate substrates (107).

10. 10. The method according to any one of claims 1 to 9, wherein the method is a continuous automated method.

11. 11. The method according to any one of claims 1 to 10, wherein the absorbent laminate web (101) has a transverse (x) extension and a longitudinal (y) extension, the transverse extension (x) corresponding to the machine direction (MD), and the tensile strength of the absorbent laminate web (101) is higher in the transverse direction (x) than in the longitudinal direction (y).

12. 12. The method of any one of claims 1 to 11, wherein each of the plurality of discrete cutting blade structures (106) of the punch roll (104) has a shape selected from an arcuate shape such as a cross, a star, a Y, or a C.

13. 13. The method according to any one of claims 1 to 12, wherein the absorbent laminate web (101) comprises at least a third layer (101c), the third layer (101c) being disposed on the first layer (101a) or between the first layer (101a) and the second layer (101b), and the third layer (101c) also being provided with the plurality of separate incisions (102).

14. 14. A wound dressing manufactured by the method of any one of claims 1 to 13, wherein the wound dressing comprises an absorbent laminate substrate (107) comprising a backing layer (108), an adhesive skin contact layer (109), and at least a first layer (107a) and a second layer (107b), wherein the first layer (107a) comprises a superabsorbent material and is provided with a plurality of separate incisions (102), and the second layer (107b) is positioned in contact with the adhesive skin contact layer (109), and the second layer (107b) is free of superabsorbent material and separate incisions (102).

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