Ostomy Pouch Welding with Woven Comfort Layer Adhesion
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Solution Overview
Problem
Existing ostomy pouches with woven comfort layers are complex, costly, bulky, and noisy, compromising discretion and comfort due to additional layers and increased production complexity.
Innovation Solution
A two-step welding process is employed to join cavity walls and a comfort layer using a hot melt adhesive coating, allowing gentler conditions for each step, reducing the risk of damage and complexity while maintaining a strong bond and discretion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional intervening wall layer is added to the pouch structure to support the woven comfort layer, then the comfort layer can be properly adhered and fraying is avoided, but the pouch complexity, cost, bulk, and noise increase
Solution Approach 1:
The patent removes the additional intervening wall layer from the pouch structure, extracting only the essential support function. Instead of adding a separate structural layer, the invention applies adhesive directly to the inner surface of the existing rear wall, thereby eliminating the redundant layer while maintaining the comfort layer's secure attachment and edge protection.
2Reliability
If a complete layer of film material is placed adjacent to the woven comfort layer, then the comfort layer is properly supported and protected, but the pouch becomes bulkier and noisier
Solution Approach 1:
The patent replaces the bulky complete film layer with a thin adhesive coating applied directly to the rear wall's inner surface. This thin film approach provides the necessary support and protection for the comfort layer while minimizing additional bulk and eliminating the rustling noise associated with larger film layers.
3Object-affected harmful factors
If a complete layer of film material is added to the pouch, then the comfort layer is protected from visibility of contents, but the pouch becomes more costly and complex
Solution Approach 1:
The patent extracts only the essential function of content visibility protection from the complete film layer, achieving this by applying adhesive directly to the rear wall's inner surface. This eliminates the need for an additional opaque layer while maintaining the comfort layer's position and opacity function.
4Ease of manufacture
If traditional welding processes are used to join the comfort layer to film layers, then assembly is simplified, but the woven comfort material cannot be properly adhered without damage
Solution Approach 1:
The patent changes the welding parameters by reducing temperature and pressure settings compared to traditional film-to-film welding. This modified welding process allows the woven comfort material to be adhered to the rear wall without damaging the delicate fabric structure, achieving both proper adhesion and material integrity.
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
The method increases the usability and discretion of ostomy pouches by reducing production complexity, cost, and noise, while ensuring a comfortable and reliable stoma management system.
Implementation Method 1
the comfort material is a fabric material with a hot melt adhesive coating thereon; joining a first cavity wall to a second cavity wall at a first temperature and a first pressure for a first time period; and subsequently, joining a comfort layer to at least one of the first and second cavity walls at a second temperature and a second pressure for a second time period
Data Source
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AI summary
A method of forming an ostomy pouch comprising: providing a film to form a first cavity wall and a second cavity wall; providing a comfort material to form a comfort layer; wherein the comfort material is a woven fabric material with a hot melt adhesive coating thereon; joining the first cavity wall to the second cavity wall at a first temperature and a first pressure for a first time period; and subsequently joining a comfort layer to at least one of the first and second cavity walls at a second temperature and a second pressure for a second time period.