Wound dressing and method for manufacturing the same

• US 20050059918A1
• Filed: 08/25/2004
• Published: 03/17/2005
• Est. Priority Date: 09/17/2003
• Status: Active Grant

• Current Assignee: Ossur hf
• Original Assignee: Ossur hf
• Inventors: Sigurjonsson, Gudmundur Fertram, Elefsen, Thordur M., Gudnason, Palmar I.
• Granted Patent: US 7,396,975 B2
• Time in Patent Office: Days
• US Class Current: 602/54
• CPC Class Codes: A61F 13/0203 with fluid retention members
• CPC Class Codes: A61F 13/0276 Apparatus or processes for manufacturing adhesive dressings or bandages
• CPC Class Codes: A61F 2013/00846 with transparent or translucent part
• CPC Class Codes: A61L 15/26 Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives thereof A61L15/225 takes precedence
• CPC Class Codes: A61L 15/34 Oils, fats, waxes or natural resins A61L15/225 takes precedence
• CPC Class Codes: A61L 15/425 Porous materials, e.g. foams or sponges
• CPC Class Codes: A61L 15/58 Adhesives
• CPC Class Codes: A61L 15/60 Liquid-swellable gel-forming materials, e.g. super-absorbents
• CPC Class Codes: C08L 83/04 Polysiloxanes

Abstract

A wound dressing defining skin facing areas having different degrees of skin adherence. The dressing comprises a backing layer defining a center portion and a border portion surrounding the center portion. A carrier layer is secured to the border portion of the backing layer within the border portion and includes a first skin adherent facing layer. An absorbent core is connected to a surface of the backing layer within the center portion and a second skin adherent facing layer is disposed along a surface of the absorbent core. The first facing layer has greater skin adhesive properties than the second facing layer.

Claims

1. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion bordering the center portion;

a carrier layer having first and second surfaces, the second surface of the carrier layer secured to the first surface of the border portion of the backing layer, the carrier layer defining an opening generally corresponding to the center portion of the backing layer; and

a first skin adherent facing layer disposed along the first surface of the carrier layer.

2. The wound dressing according to claim 1, wherein the first facing layer comprises a silicone gel.

3. The wound dressing according to claim 1, further comprising:

an absorbent core having first and second surfaces, second surface of the absorbent core secured to the first surface of the backing layer generally within the boundaries of the center portion of the backing layer and extending through the opening of the carrier layer; and

a second skin adherent facing layer disposed on the first surface of the absorbent core, said first facing layer having greater skin adherence properties than the second facing layer.

4. The wound dressing according to claim 3, wherein the second facing layer comprises a discrete layer of silicone gel having a plurality of preformed apertures arranged in a pattern.

5. The wound dressing according to claim 4, wherein the apertures of the second facing layer are generally uniformly spaced from one another and generally have a uniform shape and size.

6. The wound dressing according to claim 3, wherein the backing layer seals peripheral edge portions of the absorbent core located near and along the interface between the border and central portions of the backing layer.

7. The wound dressing according to claim 1, wherein the backing layer is a liquid impervious, moisture permeable, polymeric film.

8. The wound dressing according to claim 1, wherein the carrier layer is a liquid impervious, moisture permeable polymeric film.

9. The wound dressing according to claim 1, wherein the carrier layer and the backing layer are thermal bonded to one another.

10. The wound dressing according to claim 1, wherein the first facing layer is a pressure sensitive adhesive.

11. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion;

a first skin adherent facing layer connected to the border portion along the first surface of the backing layer;

an absorbent core having first and second surfaces, the absorbent core connected to the center portion along the first surface of the backing layer; and

a discrete second skin adherent facing layer disposed along the first surface of the absorbent core.

12. The wound dressing according to claim 11, further comprising a carrier layer interposed between the backing layer and the first facing layer, said carrier layer surrounding the center portion of the backing layer.

13. The wound dressing according to claim 11, wherein the second facing layer comprises a discrete layer of silicone gel having a plurality of preformed apertures arranged in a pattern.

14. The wound dressing according to claim 11, wherein the first facing layer comprises of a discrete layer of silicone gel.

15. The wound dressing according to claim 11, wherein the carrier layer and the backing layer are thermal bonded to one another.

16. The wound dressing according to claim 11, wherein the backing layer seals peripheral edge portions of the absorbent core located near and along an interface between the border and central portions of the backing layer.

17. The wound dressing according to claim 11, wherein the first facing layer comprises a pressure sensitive adhesive.

18. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion along the proximal surface thereof;

a carrier layer having first and second surfaces, the second surface of the carrier layer secured to the first surface of the border portion of the backing layer;

a first skin adherent facing layer disposed on the first side of the carrier layer;

an absorbent core having first and second surfaces, the second surface of the absorbent core connected to the first surface of the backing layer; and

a second skin adherent facing layer disposed along a first surface of the absorbent core;

wherein the first facing layer has greater skin adherence properties than the second facing layer.

19. The wound dressing according to claim 18, wherein the second facing layer comprises a discrete layer of apertured silicone gel.

20. The wound dressing according to claim 18, wherein the first facing layer comprises of a discrete layer of silicone gel.

21. The wound dressing according to claim 18, wherein the carrier layer and the backing layer are thermal bonded to one another.

22. The wound dressing according to claim 18, wherein the backing layer seals peripheral edge portions of the absorbent core located near and along an interface between the border and central portions of the backing layer.

23. A method for manufacturing a wound dressing, comprising the steps of:

providing a carrier layer having first and second surfaces;

applying a first skin adherent facing layer onto a portion of the first surface of the carrier layer;

removing a center portion of the carrier layer to define an opening in the carrier layer;

inserting an absorbent core within the opening of the carrier layer, said absorbent core having first and second surfaces; and

connecting a first surface of a backing layer to the second surface of the absorbent core and the second surface of the carrier layer.

24. The method according to claim 23, wherein the first surface of the backing layer is thermal bonded to the second surface of the carrier layer.

25. The method according to claim 23, wherein the step of securing the backing layer to the carrier layer and the absorbent core comprises the steps of:

providing a platen having a generally planar border region and a recessed center region relative to the border region that generally corresponds to the shape of the absorbent core;

heating the platen to an elevated temperature relative to the temperature of the carrier and backing layers;

urging the platen against the second surface of the backing layer to form pressure thereon, the pressure being sufficient to substantially cause thermal bonding of the backing and carrier layers; and

removing the platen from the second surface of the backing layer after the first surface of the backing layer has thermal bonded to the second surface of the carrier layer.

26. The method according to claim 23, wherein the absorbent core includes a second skin adherent facing layer along the first surface thereof.

27. The method according to claim 26, wherein the first facing layer has greater skin adherence properties than the second facing layer.

28. The method according to claim 26, wherein the second facing layer is a discrete layer of apertured silicone gel.

29. The method according to claim 28, wherein the second facing layer includes a plurality of preformed apertures arranged in a pattern.

30. The method according to claim 23, wherein the first facing layer is a silicone gel.

31. The method according to claim 30, wherein the step of the applying the first facing layer on the carrier layer comprises the steps of:

depositing a discrete layer of uncured silicone gel on the first surface of the carrier layer; and

curing the layer of silicone gel on the carrier layer;

32. The method according to claim 31, wherein the step of curing the silicone gel comprises applying heat to the silicone gel until it has cured.

33. The method according to claim 31, further comprising the step of depositing a silicone primer onto the first surface of the carrier layer prior to depositing the uncured silicone gel thereon.

34. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion;

a first skin adherent facing layer connected to the border portion of the backing layer along the first surface thereof;

an absorbent core having first and second surfaces, the second surface of the absorbent core connected to the first surface of the backing layer within the center portion thereof; and

a second skin adherent facing layer secured to the first surface of the absorbent core and having a plurality of apertures.

35. The wound dressing according to claim 34, wherein the first facing layer is apertured.

36. The wound dressing according to claim 35, wherein the apertures of the first facing layer have a generally uniform shape and size.

37. The wound dressing according to claim 34, wherein the apertures of the second facing layer are arranged in a predetermined pattern.

38. The wound dressing according to claim 37, wherein the apertures of the second facing layer have a generally uniform shape and size.

39. The wound dressing according to claim 34, wherein the first facing layer is directly disposed along the first surface of the backing layer.

40. The wound dressing according to claim 34, wherein the first and second facing layers have different degrees of adhesion.

41. The wound dressing according to claim 40, wherein the first facing layer has greater skin adherence properties than the second facing layer.

42. The wound dressing according to claim 34, wherein the backing layer is liquid impermeable and moisture permeable.

43. The wound dressing according to claim 34, wherein the second facing layer consists of a silicone gel.

44. A wound dressing, comprising:

backing means for preventing liquid transport therethrough and having first and second surfaces, the backing means defining a center portion and a border portion surrounding the center portion;

first facing means for adherence to skin and associated with the border portion of the backing means along the first surface thereof;

absorbing means for absorbing wound exudates and having first and second surfaces, the second surface of the absorbing means associated with the center portion of the backing means; and

second facing means for adhering to skin and associated with the first surface of the absorbing means.

45. The wound dressing according to claim 44, wherein the border portion of the backing means surrounds the entirety of the center portion thereof.

46. The wound dressing according to claim 44, wherein the first facing means comprises:

a carrier layer having first and second surfaces, the second surface of the carrier layer secured to the first surface of the border portion of the backing means, the carrier layer defining an opening generally corresponding to the center portion of the backing means; and

a first hydrophobic gel layer disposed along the first surface of the carrier layer.

47. The wound dressing according to claim 44, wherein the first facing means comprises:

a first hydrophobic gel layer disposed directly along the first surface of the backing means in at least the border portion thereof.

48. The wound dressing according to claim 47, wherein the first gel layer is disposed along the entirety of the first surface of the backing means.

49. The wound dressing according to claim 47, wherein the first gel layer has a plurality of apertures arranged in a pattern and having a generally uniform shape and size.

50. The wound dressing according to claim 44, wherein the second facing means consists of a discrete layer of hydrophobic gel.

51. The wound dressing according to claim 50, wherein the second facing means has fluid transport means for permitting fluid transport therethrough.

52. The wound dressing according to claim 51, wherein the fluid transport means of the second facing means comprises a plurality of apertures formed by the discrete layer of hydrophobic gel, said aperture arranged in a pattern and have a generally uniform shape and size.

53. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion;

a first skin adherent facing layer secured to the border portion of the backing layer along the first surface thereof;

an absorbent core having first and second surfaces, the second surface of the absorbent core connected to the first surface of the backing layer within the center portion thereof; and

a second skin adherent facing layer secured to the first surface of the absorbent core;

wherein the backing layer defines contoured outer edges, the absorbent core having contoured peripheral edges generally corresponding in shape to the contoured peripheral edges of the backing layer.

54. The wound dressing according to claim 53, wherein the entirety of the outer edges of the backing layer and absorbent core define a substantially non-linear profile.

55. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion;

a first skin adherent facing layer secured to the border portion of the backing layer along the first surface thereof;

an absorbent core having first and second surfaces, the second surface of the absorbent core connected to the first surface of the backing layer within the center portion thereof; and

a second skin adherent facing layer secured to the first surface of the absorbent core;

wherein the border portion of the backing layer defines a plurality of pleats and the center portion of the backing layer has a generally planar configuration.

56. The wound dressing according to claim 55, wherein the pleats generally taper from the peripheral outer edges of the backing layer to the periphery of the center portion of the backing layer.

57. The wound dressing according to claim 55, wherein the first skin adherent facing layer comprises a carrier layer having first and second surfaces, the second surface of the carrier layer secured to the first surface of the border portion of the backing layer, the carrier layer defining an opening generally corresponding to the center portion of the backing layer.

58. The wound dressing according to claim 57, wherein the carrier layer and the backing layer are moisture permeable and liquid impermeable.

59. The wound dressing according to claim 57, wherein the first hydrophobic gel layer defines a plurality of apertures arranged in a pattern and has generally uniform shape and size.

60. The wound dressing according to claim 55, wherein the second facing layer consists of a discrete layer of hydrophobic gel defining a plurality of apertures arranged in a pattern and having generally uniform shape and size.

61. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion;

a first skin adherent facing layer secured to the border portion of the backing layer along the first surface thereof;

an absorbent core having first and second surfaces, the second surface of the absorbent core connected to the first surface of the backing layer within the center portion thereof; and

a second skin adherent facing layer secured to the first surface of the absorbent core;

wherein the absorbent core defines an undulating profile and the center portion of the backing layer generally follows the profile of the absorbent core.

62. The wound dressing according to claim 61, further comprising a plurality of discrete hydrophilic particles disposed in the absorbent core.

63. The wound dressing according to claim 62, wherein the absorbent core is hydrophilic foam.

64. The wound dressing according to claim 61, wherein the first skin adherent facing layer comprises a carrier layer having first and second surfaces, the second surface of the carrier layer secured to the first surface of the border portion of the backing layer, the carrier layer defining an opening generally corresponding to the center portion of the backing layer;

and

a first hydrophobic gel layer disposed along the first surface of the carrier layer.

65. The wound dressing according to claim 64, wherein the border portion of the backing layer is substantially planar.

66. The wound dressing according to claim 61, wherein the border portion of the backing layer defines a plurality of corrugations.

68. The wound dressing according to claim 66, wherein the corrugations are arranged in a plurality of rows.

67. A wound dressing, comprising:

a backing layer having first and second surfaces, the backing layer defining a center portion and a border portion surrounding the center portion;

a first skin adherent facing layer connected to the border portion of the backing layer along the first surface thereof;

an absorbent core having first and second surfaces, the second surface of the absorbent core connected to the first surface of the backing layer within the center portion thereof; and

a second skin adherent facing layer secured to the first surface of the absorbent core;

wherein the backing layer has a corrugated profile in at least the border portion thereof.

69. The wound dressing according to claim 67, further comprising a carrier layer having first and second surfaces, the second surface secured to the border portion of the backing layer, the carrier layer defining an opening generally corresponding to the center portion of the backing layer with the absorbent core extending therethrough.