Contoured Wound Dressing Manufacturing via Gear Pump Deposition

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Solution Overview

Problem

Existing methods for manufacturing contoured wound dressings are time-intensive and costly due to wastage of adhesive and protective cover and release sheet webbing, and require complex processing steps and multiple molds.

Innovation Solution

A continuous in-line method using a gear pump to deposit heated adhesive in a predetermined shape and thickness onto a protective release paper, followed by lamination with a roller of specific firmness to create a contoured dressing without sticking issues, eliminating the need for compression and multiple molds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If extrusion and compression techniques with molds are used to form hydrocolloid dressings, then the desired shape and contour are achieved, but adhesive and webbing are wasted and production becomes costly

Engineering Contradiction:

Improveshape and contour precisionVSAvoidadhesive and webbing waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The adhesive is deposited in the predetermined shape and thickness required for the final dressing before lamination occurs. The gear pump extrudes adhesive directly into the contour needed for the border edge, eliminating the need for subsequent compression molding and preventing material waste from trimming and flashing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The contouring function is extracted from the compression molding step and integrated into the adhesive deposition process itself. The gear pump nozzle is shaped to extrude adhesive in the precise contour needed, separating the shaping function from the lamination and compression functions.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If multiple processing steps including compression molding are used, then contoured dressings are formed, but production time increases and efficiency decreases

Engineering Contradiction:

Improvecontour formationVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The adhesive deposition and contouring operations are merged into a single step using the gear pump with a contoured nozzle. The adhesive is extruded in the final required shape directly onto the release sheet, eliminating separate compression molding and contouring steps that would slow production.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The gear pump continuously extrudes adhesive in the predetermined contour as the release sheet moves through the system, maintaining continuous production flow without interruption for molding, heating, or shaping operations that would break the continuous action.

Inventive Principle:

Principle #20Continuity of useful action

3Strength

If heated adhesive is extruded and then compressed using molds, then the adhesive sets into shape, but energy consumption increases

Engineering Contradiction:

Improveadhesive bonding strengthVSAvoidheating and compression energy

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The adhesive is deposited in the final required shape and thickness before lamination, eliminating the need for subsequent compression molding. The adhesive sets into the predetermined contour during the lamination process itself, reducing the need for additional heating and compression energy.

Inventive Principle:

Principle #10Preliminary action

4Shape

If contoured rollers with molds are used for shaping, then the desired contour is achieved, but the adhesive sticks to the roller and requires cleaning

Engineering Contradiction:

Improveborder edge contourVSAvoidroller maintenance

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The adhesive is extruded in the final contour shape directly from the gear pump nozzle before contact with any roller surface. The lamination roller simply presses the coverstock onto the already-shaped adhesive, preventing the adhesive from sticking to the roller while maintaining the contoured border edge.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method reduces energy and time consumption, eliminates wastage, and enables cost-effective production of various shaped dressings at high speeds with no adhesive or webbing waste, improving efficiency and reducing production costs.

Implementation Method 1

The adhesive, which is preferably heated, is deposited in a predetermined shaped and thickness onto a protective release paper

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

The adhesive is deposited then laminated with a protective cover film using a roller with a predetermined firmness under a predetermined pressure

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS9827146B2Manufacturing method for wound dressings

Publication Date: 2017.11.28 SARASOTA MEDICAL PRODUCTS INC

AI summary

A wound dressing having a thin barrier layer of soft, pliant adhesive material with a flexible cover layer extending along one side of the adhesive layer and a removable release sheet on the opposite side is disclosed. The adhesive material has a center and border surrounding the center such that the adhesive is contoured. A method for making the contoured dressing using a gear pump and a laminating roller having a predetermined softness and firmness is also disclosed.