Screen Printing Silicone Adhesive Layers for Ostomy Devices
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Solution Overview
Problem
Conventional manufacturing methods for silicone adhesives are wasteful and inefficient, particularly in producing thin layers suitable for skin contactable applications like ostomy devices, where secure adhesion and non-traumatic removal are critical, and the existing methods do not allow for recycling of cured silicone material.
Innovation Solution
A screen printing method and apparatus that deliver and cure liquid or gel phase silicone material onto a substrate, enabling the production of thin, uniform layers with precise control over thickness and shape, compatible with various polymer types, including condensation and addition curable materials, and allowing for lamination with additional layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional multi-stage manufacturing methods are used to produce silicone adhesive layers, then the adhesive can achieve secure skin adhesion, but the process generates significant material waste and cannot recycle cured silicone material
Solution Approach 1:
The patent changes the physical state parameter of silicone material from cured solid to liquid or gel phase during manufacturing, enabling direct deposition of thin layers without cutting or punching. This parameter change allows the material to be applied in its uncured state and then cured in place, eliminating waste from conventional cut-and-punch methods
Solution Approach 2:
The patent replaces mechanical cutting and punching operations with a liquid deposition and curing system. Instead of mechanically removing material to achieve desired shapes, the system uses liquid silicone delivered through a print head that deposits material only where needed, followed by in-situ curing to create the final adhesive layer
2Productivity
If conventional cutting and punching methods are used to create adhesive layers, then the desired shape can be achieved, but the process is time-consuming and generates waste material
Solution Approach 1:
The patent performs preliminary action by delivering and depositing the silicone material in the liquid or gel phase directly onto the substrate in the desired configuration before curing. This preliminary deposition of precisely shaped material eliminates the need for subsequent cutting or punching operations, as the material is already in its final shape before curing
Solution Approach 2:
The patent inverts the conventional manufacturing sequence by applying material first in a liquid or gel state that can be easily deposited and shaped, then curing it in place. This is the reverse of the conventional approach where material is cured first and then cut or punched into shape, thereby eliminating waste generation
3Manufacturing precision
If thick layers of silicone material are produced and then cut to shape, then adequate adhesion can be achieved, but the process cannot produce thin uniform layers efficiently
Solution Approach 1:
The patent changes the viscosity parameter of the silicone material to a liquid or gel phase that allows for precise control of layer thickness during deposition. This parameter change enables the material to be deposited as thin uniform layers directly onto the substrate, eliminating the need to produce thick layers and then cut them down to the required thickness
Solution Approach 2:
The patent replaces mechanical cutting operations with a controlled liquid deposition system. Instead of producing thick layers and mechanically removing material to achieve desired thickness, the system uses a print head to deposit material at controlled rates and thicknesses directly, followed by curing to create the final thin uniform adhesive layer
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 enables efficient production of silicone layers with enhanced moisture management properties, reducing processing time, material waste, and energy consumption, while ensuring secure adhesion and easy removal, suitable for skin contactable applications like ostomy devices.
Implementation Method 1
allowing the silicone material to cure on the substrate as a layer
Data Source
AI summary
Apparatus and method for the screen printing manufacture of a layer of silicone material. The method and apparatus provide for the deposition of a layer of silicone material having a controllable thickness and shape profile as determined by a template forming part of a screen printing assembly. The present apparatus and method provide a fully controlled automated or semi-automated manufacturing process enabling the deposition of a silicone layer onto a substrate layer serving as a conveyor to transport the silicone layer between different units of the process line including a heating/curing unit, a drying unit and a lamination unit.