Ostomy Pouch Welding With Woven Comfort Layer Integration
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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 method involving a two-step welding process using a hot-melt adhesive-backed woven comfort layer, where the first cavity walls are joined at a lower temperature and pressure, followed by joining the comfort layer to the cavity walls under gentler conditions, reducing production complexity and cost while maintaining discretion and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a woven comfort layer is used in the ostomy pouch, then comfort and aesthetic appeal are improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines the comfort layer and front wall into a single integrated component made from heat-releasable material. This merging eliminates the need for separate assembly steps and reduces production complexity while maintaining the comfort benefits of woven materials against the skin.
Solution Approach 2:
The heat-releasable material serves multiple functions: it provides comfort against the skin, forms the front wall structure, and enables easy separation when drainage is needed. This multi-functionality reduces the number of components needed and simplifies the overall device structure.
2Loss of information
If additional film layers are added to the pouch structure, then visibility and content inspection are improved, but device complexity and bulk increase
Solution Approach 1:
The patent makes the front wall dynamic by using heat-releasable material that can be easily separated from the comfort layer. This allows the front wall to transition between attached and detached states, enabling content inspection without requiring multiple permanent layers or complex opening mechanisms.
Solution Approach 2:
The front wall is designed to be temporarily discarded (separated) from the comfort layer when drainage or inspection is needed. This temporary separation provides visibility of contents without requiring permanent additional layers, and the front wall can be recovered or replaced as needed.
3Ease of manufacture
If the comfort layer edges are left exposed, then ease of manufacture is improved, but fraying and durability are worsened
Solution Approach 1:
The comfort layer and front wall are merged into a single integrated component made from heat-releasable material. This integration eliminates exposed edges of the comfort layer, as the front wall material covers and protects the edges while maintaining ease of manufacture through the bonding process.
4Adaptability or versatility
If multiple separate components are used in the pouch, then adaptability and functionality are improved, but device complexity and noise increase
Solution Approach 1:
The heat-releasable material provides multiple functions within a single component: it serves as the comfort layer against the skin, forms the front wall for structure and visibility, and enables drainage through heat-activated separation. This multi-functionality reduces the number of separate components needed, thereby reducing noise and complexity.
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 enhances ostomy pouch durability, reduces noise, and increases user confidence by providing a discreet and comfortable solution with reduced environmental waste through extended pouch use and reliable stomal output management.
Implementation Method 1
providing a comfort material to form a comfort layer, wherein 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
Implementation Method 2
joining a first cavity wall to a second cavity wall at a first temperature and a first pressure for a first 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.