WO1999043279A1

WO1999043279A1 - Thin film wound dressing and method for making same

Info

Publication number: WO1999043279A1
Application number: PCT/US1999/002845
Authority: WO
Inventors: Robert W. Sessions; Rainer Schmeichel
Original assignee: Ferris Mfg. Corp.
Priority date: 1998-02-27
Filing date: 1999-02-10
Publication date: 1999-09-02
Also published as: CA2321491A1; AU729366C; US6346653B1; EP1058526A4; AU2668399A; US6043406A; AU729366B2; CA2321491C; EP1058526A1

Abstract

A non-stretching wound dressing (10) is provided for use with a patient. The wound dressing includes a cover sheet (16) having top, and bottom sides, a thin film sheet (34) formed on the bottom side of the cover sheet, the film sheet having first, and second ends (24, 26), an adhesive side (23), and a carrier sheet (18) in adjacent contact with the adhesive side of the thin film sheet. The dressing also includes a first gripping tab (32) attached to one end of the thin film sheet, disposed between the film sheet, and the carrier sheet for separating the carrier sheet from the film sheet with the cover sheet remaining affixed to the film sheet. A second gripping tab (36) is attached to the top side of the cover sheet, and at one end of the cover sheet so that pulling on the second gripping tab releases the cover sheet from the film sheet with the film sheet remaining in place on the patient.

Description

THIN FILM WOUND DRESSING AND METHOD FOR MAKING SAME

FIELD OF THE INVENTION

The present invention relates to wound dressings and methods for

making such wound dressings and, in particular, to a thin film wound dressing

which can be applied to a patient without stretching, and a method for the

continuous production of a large number of such wound dressings.

BACKGROUND OF THE INVENTION

Wound dressings, consisting of a urethane film having adhesive on one

side for carrying an absorbent pad and adhering to a patient's skin

surrounding an open wound, are known in the art. The flexible nature of the

urethane film permits the dressing to conform to virtually any contour of the

patient's skin at the location where the dressing is applied. The flexibility and

thinness of the urethane film, however, present the problem of applying the

wound dressing to the patient without stretching the urethane film. Stretching

of the dressing prior to or during application to a patient may momentarily

expand the stretchable urethane film and, even though the dressing may

appear smooth when applied to the patient, it will very quickly contract after

the stretching forces are relieved, thereby causing discomfort to the patient

and irritation to the area surrounding the wound. On weak or damaged skin,

as in the elderly, the stretching forces may even cause abscesses or other skin

damage. 2

One proposed solution to the stretching problem has been to use

heavier or thicker urethane films. Unfortunately, heavier urethane films are

undesirable as a wound dressing due to decreased flexibility and less gas

permeability. Many conventional urethane films are about 1.0 mil or more

thick. Although thinner urethane films will achieve greater gas permeability,

moisture vapor transmission rates and increased flexibility and comfort, use of

such thin films has been unsuccessful because they are relatively fragile and

consequently difficult to work with during manufacture and assembly of the

wound dressing.

Another proposed solution to this problem is to attach a flexible but

non-stretching backing sheet to the urethane film using adhesive. The backing

sheet remains in contact with the urethane film while the dressing is being

applied to the patient, thereby eliminating stretching during application of the

dressing. After the wound dressing has been attached to the patient, the

backing sheet is subsequently peeled from the urethane film. Unfortunately,

methods using adhesive to attach the urethane film to conventional backing

sheets have been unable to handle the fragile and thin urethane films.

Another problem encountered when applying the polyurethane film to

the wound is maintaining the sterility of the dressing during the application

process. Previous products such as a polyurethane film wound dressings

Ensure-IT (Deseret Medical, Inc.) and POLYSKIN^® transparent dressing

(Kendall Company, Boston, Massachusetts) required contact between fingers 3

and the adhesive surface of the polyurethane film during application. It will

be appreciated that such contact is undesirable as it may potentially

contaminate the urethane film.

OBJECTS AND SUMMARY OF THE INVENTION

In view of the foregoing, it is an object of the present invention to

provide a wound dressing which provides ease of application while

maintaining sterility of the urethane film and the absorbent pad.

Another object of the invention is to provide a tab system that allows

support of the non-stretchable wound dressing following removal of the

carrier sheet. A related object is to provide a wound dressing having a tab

system that allows manipulation of the wound dressing without contaminating

contact between the sterile urethane film and the user's fingers.

One object of the invention is to provide a wound dressing having a tab

system that permits application of the wound dressing with one hand.

Yet another object of the invention is the coding of the tabs to indicate

the sequential order of utilization of the tabs.

Still another object of the present invention is to provide a wound

dressing having a unique thin urethane film which enhances healing and

maximizes gas permeability with the patient's skin. A more specific object is

to provide a thin urethane film having a thickness of about 1.0 mil or less. 4

It is an object of the present invention to provide a thin film, non-

stretchable wound dressing which can be manufactured by overlying a series

of continuous strips.

In accordance with these objects, the present invention provides a non-

stretchable wound dressing consisting of a thin film of material such as

polyurethane which is less than about 1.0 mil thick, more preferably about

0.75 mils thick, and most preferably less than about 0.75 mil thick. The

wound dressing has a non-stretchable cover sheet, such as MYLAR^®, onto

which the urethane film is cast.

The urethane film has an adhesive side and first and second releasable

ends. The adhesive side of the first releasable end receives a first gripping

tab, which extends outboard of the left releasable end of the cover sheet. The

cover sheet and first gripping tab are in adjacent contact with each other but

are not adhesively attached so that they may be freely separated from each

other. A second gripping tab may be attached to the other side of the urethane

film. The adhesive side of the second releasable end receives an intermediate

liner. An absorbent pad is centrally positioned on the urethane film. Finally,

a carrier sheet is attached to the urethane film surrounding the pad. thereby

covering and protecting the sterility of the pad.

In order to apply the wound dressing, the user pulls the first gripping

tab which lifts the combination urethane film/cover sheet from the release

surface of the carrier sheet, thereby exposing the adhesive side of the urethane 5

film. Holding the first tab and, if necessary, the intermediate liner end to

prevent the user's fingers from contacting the urethane film or absorbent pad,

the user places this layered sheet combination over the wound. The cover

sheet prevents the urethane sheet from stretching while permitting the

urethane film to contact and conform to the contours of the patient^'s skin.

After the combination urethane film/cover sheet has been placed over the

wound, the second gripping tab may be peeled away from the other side of the

urethane film without stretching or wrinkling thereof. The first and second

releasable ends may then be removed, leaving the wound dressing in proper

contact with the patient^'s skin.

An object of the invention is to provide a method of manufacturing

wound coverings incorporating thin urethane films. In a preferred

embodiment, the thin urethane films are less than about 1.0 thick and in a

more preferred embodiment, about 0.75 mils thick.

DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a top view of a wound dressing in accordance with the

present invention.

FIG. 2 is a cross-sectional view of the wound dressing taken along line

2-2 in FIG. 1.

FIG. 3 is a partially exploded view of the wound dressing shown in

FIG. 2. 6

FIGS. 4-6 are sequential views showing the application of the wound

dressing to a wound. Specifically, FIG. 4 shows the carrier sheet being peeled

away from the layered wound dressing and cover sheet.

FIG. 5 shows the adhesive side of the urethane film placed in adjacent

contact with the patient's skin and the cover sheet being peeled away from the

urethane film.

FIG. 6 shows the ends of the urethane film being pulled away from the

finished wound dressing.

FIGS. 7-11 are sequential schematic views showing one embodiment

of a method for manufacturing the wound dressing. Specifically, FIG. 7

shows a tri-layered sheet consisting of a cover sheet, a thin urethane film, and

an intermediate liner.

FIG. 8 shows the urethane film after removal of a portion of the left

urethane end and a portion of the intermediate liner, and formation of the

urethane first and second releasable ends.

FIG. 9 shows the absorbent pad attached to the adhesive side of the

urethane film.

FIG. 10 shows the first gripping tab attached to the adhesive side of the

first releasable end of the urethane film.

FIG. 11 shows the carrier sheet being positioned into contact with the

adhesive side of the urethane film, and the second tab attached to the cover

sheet. 7

While the invention will be described and disclosed in connection with

certain preferred embodiments and procedures, it is not intended to limit the

invention to those specific embodiments. Rather, it is intended to cover all

such alternative embodiments and modifications as fall within the spirit and

scope of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the figures, and particularly to FIGS. 1-3, a wound

dressing 10 is provided in accordance with the present invention. The wound

dressing 10 consists of a substantially tri-layered sheet combination 12, the

combination generally consisting of a middle urethane film 14 sandwiched

between an upper cover sheet 16 and a bottom carrier sheet 18 which extend

along substantially the entire length of the wound dressing 10.

The top layer of the wound dressing 10 is a non-stretchable but flexible

cover sheet 16, which is sufficiently flexible so it does not interfere with the

ability of the urethane film 14 to conform to the contour of the patient P. The

cover sheet 16 may be comprised, for example, of MYLAR^® polyester film,

but other materials will be known to those skilled in the art.

The bottom layer of the wound dressing 10 consists of a carrier sheet

or bottom liner 18. The carrier sheet 18 is preferably made of plastic, but in

other embodiments may be made of relatively heavy paper. The bottom

carrier sheet 18 has a release side 20 which has means for facilitating release 8

of the urethane film 14 from the carrier sheet 18. In one embodiment, the

release means comprises a silicon release coating on the release side 20, but

other release means and treatments will be known in the art.

In accordance with certain objects of the present invention, the cover

sheet 16 carries a thin urethane film 14 which is preferably less than about 1.0

mil thick, more preferably about 0.75 mil thick and, most preferably, less than

about 0.75 mil thick. The thin urethane film 14 has a greater moisture vapor

transmission rate (MVTR) than conventional relatively thick urethane films

used in wound dressings of the type described herein. It will, of course, be

appreciated that maximizing the MVTR enhances breathability of the wound

dressing 10 and wound healing. The thin film 14 also conforms more

effectively to the contour of a patient's skin and, once applied to the skin,

more effectively flexes in response to movement of the patient's skin than

conventional thick urethane films. The thin film is referred to as a "urethane"

film, but other suitable materials are known in the art. In one embodiment, a

suitable material for the film sheet may be urethane film (medical grade).

In order to handle the relatively fragile thin urethane film 14 during

manufacture, the urethane film 14 is preferably formed or cast directly on the

cover sheet 16. Once cast on the cover sheet 16, the unitary cover sheet 16

and thin urethane film 14 may be used in subsequent manufacturing steps

without stretching, tearing or otherwise destroying the thin urethane 14.

Moreover, unlike many prior wound dressings, it is not necessary to separate 9

the urethane film 14 from a conventional backing sheet or subsequently use

adhesive to attach the cover sheet 16 and urethane film 14 together. When it

is necessary, the cover sheet 16 and urethane film 14 may be removed simply

by pulling the two layers apart, thereby overcoming the attractive forces

which normally keep the two layers together.

As best shown in FIG. 8, the urethane film 14 consists of a middle

portion 22 and two releasable ends which will be generally referenced as first

or left releasable end 24 and second or right releasable end 26. The urethane

film 14 has an adhesive side 28 to which an appropriate conventional adhesive

is applied. As best shown in FIGS. 1 and 10, the middle portion 22 is thus

capable of receiving and carrying an absorbent pad 30 which is centrally

disposed on the wound dressing 10. Referring to FIG. 1, it will be seen that

the illustrated pad 30 has a generally rectangular shape centrally disposed in

the middle of the middle portion 22. It will be appreciated that the outer

periphery of the middle portion 22 remains uncovered so that the adhesive

side 28 may engage the bottom carrier sheet 18, permitting the combination of

the cover sheet 16/urethane film 14 to be releasably attached to the carrier

sheet 18 as best shown in FIGS. 1-2.

Although the absorbent material 30 shown in the figures is rectangular,

it may have any desirable shape including a square, circle, diamond, ellipse or

the like. The absorbent material 30 may be gauze, sponge or other inert

absorbent material which is suitable for absorbing moisture from the wound 10

area. The presence of an absorbent material or a hydrophilic absorbent

material patch not only serves as an absorbent, it also serves as an insulating

material that holds the body's warmth at the wound site. This increased

warmth due to the patch facilitates a more rapid healing of the wound. The

absorbent material 30 may be clear or opaque to conceal the wound area.

Among the hydrophilic absorbent materials which may be suitable are poly

(D-Glucosamine) from Bentech Laboratories and ARASORB™ 720

superabsorbent polymer from Arakawa Chemical Inc., Chicago, Illinois, and

WATERLOCK™ A-222; A- 100, D-212, D-242, G400 and WATERLOCK B,

C and H from Grain Processing Corporation.

In other embodiments, the absorbent material 30 may contain

medication. The medication may be an antibiotic, a healing promoting agent,

an anti-inflammatory agent, a transdermal diffusable pharmaceutical, a

coagulant or an anti-coagulant. Anticipated antibiotics include typical

bacteriostatic and bactericidal agents, anti-fungal and anti-viral agents.

Among the anti-bacterial agents and anti-fungal agents are the penicillins,

streptomycins, sulfuramides, cephalosporins, kanamycins, gentaminicin,

tobramycin, neomycin, paromomycin, chloramphenicol, tetracyclines,

lincomycin, novobiocin, nalidixic acid, rifamycins, polymyxin B,

griseofulvin, pimaricin, cony statin, amphotericin B; and for viruses rifamycin,

nucleic acid analogs, arabinosylthymine, 5-iodo-5'amino-2'-5' dideoxycridine,

arabinosyl adenine, arabinosyl cytosine, acycloguanosine, ribavirin, 11

phosphono acetic acid, and idoxuridine. Among healing promoting agents are

growth promoting hormones, among them epidermal growth factor and

urogastrone. Among the anti-inflammatory agents are the corticosteroids.

Among the transdermal diffusable pharmaceuticals are nitroglycerin, and

other cardiac and blood pressure affecting agents. Among the coagulants are

the blood clotting factors and activators of the intrinsic or extrinsic clotting

pathways. Among the anti-coagulants are heparin, citric acid, protamine

sulfate. and other inhibitors of blood clotting. Also useful as anti-blood

clotting agents are thrombolytic enzymes such as streptokinase and urokinase.

Referring again to FIGS. 2-3, the adhesive side 23 of the left and right

releasable ends 24, 26 are capable of receiving and carrying first tab 32 and an

intermediate liner 34, respectively. The intermediate liner 34, disposed

between the cover sheet 16 and the carrier sheet 18, covers substantially all of

the right releasable end 26 so that the adhesive side 28 of the right releasable

end 34 does not adhere to the carrier sheet 18. The first tab 32, which extends

outboard of the left end of the cover sheet 16, is similarly disposed between

the cover sheet 16 and the carrier sheet and covers substantially all of the left

releasable end 24 so that the adhesive side 28 of the left end 24 does not

adhere to the carrier sheet 18. The faces of the first tab 32 and the

intermediate liner 34 in adjacent contact with the carrier sheet 18 do not carry

an adhesive so that they do not adhere to the release side 20 of the carrier

sheet 18. 12

Means is provided for removing the left and right releasable ends 24,

26 of the urethane film 14 after the wound dressing 10 is applied to a wound.

In the illustrated embodiment, the left releasable end 24 is perforated along

the first or left release line 24a and the right releasable end 26 is scored along

the second or right release line 26a. Thus, the release lines 24a, 26a are

substantially weaker than the remaining urethane film 14 and will tear away

from the middle portion 22 of the urethane film 14. Generally, the perforated

line 24a is slightly stronger than the scored line 26a so that scored line 26a

will be removed first when the two releasable ends 24, 26 are simultaneously

pulled with equal force. Of course, other methods may be used to permit

removal of the two releasable ends 24, 26, including, for example,_scoring or

perforating both release lines.

A second gripping tab or strip 36 may be bonded at one end of the

cover sheet 16 by any suitable adhesive. Referring to FIGS. 1-2, it will be

seen that, in the illustrated embodiment, the second tab 36 and the left end of

the cover sheet 16 are inboard of the first tab 32 so that first tab 32 may be

more easily grasped by a user to separate the combination of the upper cover

sheet 16/urethane film 14 from the bottom carrier sheet 18.

FIGS. 4-6 schematically show the application of a wound dressing 10

made in accordance with the present invention to a wound on a patient P.

Referring first to FIG. 2, it will be appreciated that the first tab 32 is

positioned outboard of the second tab 36 so that the user may more easily 13

grab the first tab 32 without grabbing the second tab 36. In order to apply the

wound dressing 10 to a wound on a patient P, the first tab 32 is gripped and

pulled to facilitate separation of the layered upper urethane film 14/cover

sheet 16 from the bottom carrier sheet 18. The first tab 32, which is not

tacky, is interposed between the adhesive side 28 of the urethane film 14 and

the release surface 20 on the carrier sheet 18 to promote the initial separation

of the urethane film 14 from the carrier sheet 18. In response to the

combination of the release surface 20 and the non-tacky first tab 32, pulling

on the first tab 32 causes release of the urethane adhesive side 28 from the

release surface 20, with the cover sheet 16 still adhering to the opposite side

of the urethane film 14. The user may then grip the first tab 32 and, if

necessary, the intermediate liner 34 to place the remaining combination of the

urethane film 14/cover sheet 16 over the wound of a patient P as generally

shown in FIG. 5. Once the adhesive side 28 of the middle portion 22 of the

urethane film 14 contacts the skin, the adhesive side 28 sticks to the patient's

skin. The user's fingers therefore need never come into contact with the

adhesive layer 28 which will be placed against the patient's skin, thereby

maintaining sterility of the wound dressing 10.

Moreover, the presence of the cover sheet 16 adjacent the thin urethane

film 14 permits the wound dressing 10 to be placed adjacent the patent's skin

and wound without stretching, wrinkling, or tearing the thin and relatively

fragile urethane film 14. The cover sheet 16 is sufficiently flexible so as not 14

to interfere with the ability of the urethane film 14 to conform to the contour

of the patient P. The presence of cover sheet 16 also ensures the even

application of the wound dressing 10 to the patient P surface by promoting

evenly distributed tension between the cover sheet 16 and the urethane film

14, despite the tension created in response to manipulation of the first tab 32.

This even release ensures that the urethane film 14 will not be distorted by

excessive stresses exerted on any one region of the urethane film 14. It will

thus be appreciated that the user must first release non-tacky tab 32 to

overcome the attractive forces between the film 14 and the cover sheet 16.

Once in place, the adhesion of the urethane film 14 to the patient's skin

is greater than the adhesion between the urethane film 14 and the cover sheet

16. Thus, as shown in FIG. 5, the second tab 36 can be pulled to separate the

cover sheet 16 from the urethane film 14, thereby removing the cover sheet 16

and leaving the thin urethane film 14 adhering to the patient P. In order to

promote the initial separation of the cover sheet 16 from the urethane film 14,

it will be seen upon reference to FIG. 3, for example, that the non-tacky first

tab 32 is adjacent to the non-tacky cover sheet 16. In contrast, the right end of

the cover sheet 16 is in adjacent contact with the urethane film 14.

In the illustrated embodiment, the first tab 32 and the intermediate liner

34 are interposed between the adhesive side 28 of the urethane film 14 and the

patient's skin to prevent the releasable end tabs 24, 26 from adhering to the

patient's skin. Accordingly, the user may pull the left releasable end 24 (and 15

first tab 32) and right releasable end 26 (and intermediate liner 34) away from

the wound dressing 10 wherein the release means at the release lines 24a, 26a

facilitates removal of releasable ends 24, 26 without disturbing the wound

dressing 10 or the wound.

It should now be appreciated that the present invention, in accordance

with certain objects of the invention, leaves a finished wound dressing 10

comprising a thin urethane film 14 and absorbent pad 30 on the wound area

without stress areas or microbial contamination of the wound area.

In accordance with certain objects of the present invention, the tabs 32,

36 may bear an indicia indicating the order of use. The first tab 32 may bear

an indicia indicating it is the first tab 32 in the two tab system. Similarly, the

second tab 36 may contain an indicia indicating it is the second tab 36 in the

two tab system. Indicia useful for marking on the two tab system that allow

the error free application of the wound dressing 10 include color codes such

as a blue first tab, a red second tab and a white intermediate liner, or numeric

or alphanumeric references such as 1, 2, 3; I, II, III; A, B, C; Tab 1, Tab 2,

Tab 3; First, Second, Third; Pull First, Pull Second, Pull Third; and the like.

In accordance with other objects of the present invention, this two tab system

allows the application of the wound dressing 10 using only one hand,

particularly valuable for self-application to the hand or arm. Two hands are

used to remove the carrier sheet 18, by holding the first tab 32. The hand

holding the first tab 32 may then apply the wound dressing 10 and remove the 16

flexible cover sheet 16 by pulling on the second tab 36. Finally, the ends 24,

26 of the urethane film 14 may be removed by separating along the release

lines 24a. 26a.

The present invention also meets a long-felt need for a thin film wound

dressing 10 which increases gas permeability which is necessary for increased

healing rates and also patient comfort. This wound dressing 10 can be easily

and safely applied to any type of wound or to an intravenous site. The

transparent construction of the cover sheet 16 and urethane film 14 allow

visual observation of the wound site during application and while on the

patient P. The cover sheet 16 and tabs 32, 34 provide support for the wound

dressing 10 until after application wherein the cover sheet 16 can then be

removed easily using the two tab application system without distorting or

stretching the film sheet affixed to the patient surface or skin. If necessary,

the wound dressing 10 can be applied with one hand. The tabs may be

optionally marked with indicia indicating the order of utilization, thereby

permitting error free application on the first attempt even by the

inexperienced.

FIGS. 7-11 schematically show a method for manufacturing the wound

dressing 10. Generally, the wound dressing may be manufactured using rolls

or webs of material and assembling such webs in successive layers to form

the wound dressing 10. The various components are applied over each other

in connected layers. 17

Referring to FIG. 7, a web of sandwiched thin urethane film 14 may be

made by forming or casting a urethane film 14, having the desired thickness,

on a cover sheet 16 in a conventional manner. The thin urethane film 14

preferably has a thickness of less than about 1.0 mil, more preferably about

0.75 mil, and most preferably less than about 0.75 mil. It will, of course, be

appreciated that, in other embodiments, the thickness of the urethane film 14

may be greater than about 1.0 mil. The cover sheet 16 is preferably made

from a plastic material, but other conventional materials, such as paper, may

be used. The formation process creates sufficient attractive forces to permit

the urethane film and cover sheet to remain in adjacent contact during

subsequent manufacturing steps while permitting a user to manipulate the film

and to peel the film from the cover sheet. It is preferable that the urethane

film and cover sheet be attached to each other without adhesives. However,

in other embodiments, an adhesive may be used to attach the urethane film

and cover sheet in which case, a preformed urethane film must be brought into

adjacent contact with the cover sheet. An adhesive may be applied to the

adhesive side 28 of the urethane film 14 so that an intermediate liner 34 may

be attached to and cover the urethane film 14 for mechanical protection of the

membrane 14 and to protect against contamination during subsequent storage

and processing steps. The sandwiched urethane film 14 is typically formed

into rolls or webs 112. 18

The triple-layered web 112 may subsequently be processed to separate

portions of some of the layers as generally shown in FIG. 8. More

specifically, the intermediate liner and the urethane film are cut and removed

from the left end of the web 112 to form the releasable end 24. The tri-

layered web 112 is subsequently scored and/or perforated at release lines 24a

and 26a to form the left and right releasable ends 24, 26 and to properly size

the middle portion 22 of the wound dressing 10. Referring to FIGS. 8-9, it

will be seen that the remaining portion of the intermediate liner 34 now covers

only the right releasable end 26 of the urethane film 14. The trimmed tri-

layered web 112 is subsequently processed to receive the absorbent pad 30,

the first tab 32 and the carrier sheet 18, as schematically shown in FIGS. 9-10.

Pre-sized absorbent material 30 may be inserted into the predetermined

position on the urethane film 14. Specifically, the cut absorbent pad 30 are

inserted at a predetermined and typically centered position relative to the

release lines 24a, 26a defining the wound dressing 10. The adhesive side 28

of the urethane film 14 securely engages and holds the absorbent pad 30.

A web of the first tab 32 may be pressed into adjacent contact with the

left releasable end 24 of the urethane film 14. More specifically, the right

portion of the first tab 32 (as shown in the figures) is positioned so that it is

substantially adjacent to or slightly outboard of the release line 24a. It is

undesirable for the first tab 32 to be positioned on or inboard of the release

line 24a because it will interfere with the separation of the left releasable end 19

24 from the wound dressing 10. The left portion of the first tab 32 is

positioned outboard of the cover sheet 16. It will be appreciated that the left

releasable end 24 is disposed between the cover sheet 16 and the first tab 32,

but there is nothing between the cover sheet 16 and the left portion of the first

tab 32.

A web of the bottom carrier sheet 18 may be supplied so that the

release side 20 is brought into contact with adhesive side 28 of the urethane

film 14 as schematically shown in FIG. 11. It should now be appreciated that

the carrier sheet 18 is releasably attached to the portions of the adhesive side

28 which are not covered by the absorbent pad 30, thereby securing the carrier

sheet 18 and the urethane film 14 together. Referring to FIG. 11, it will be

seen that the right portion of the carrier sheet 18 liner is slightly inboard of the

right releasable end 26 of the cover sheet 16. The left portion of the carrier

sheet 18 is substantially inboard of the first tab 32.

The second tab 36 may be attached to the top side of the cover sheet

16. It is preferable that the second tab 36 have an adhesive side 28 which is

attached to the left end 24 of the cover sheet 16 as generally shown in FIG.

11, although other methods may apply the adhesive to the upper side of the

cover sheet.

The size ranges of wound dressings 10 can vary from 0.20 x 1.0 inch to

18 x 18 inches. Preferred sizes of wound dressing 10 are 1 " x 3", 2" x 3", 3"

x 4", 4" x 5", 6" x 8", 10" x 12", 12" x 18". 20

Although modifications and changes may be suggested by those skilled

in the art, it is the intention of the inventor to embody within the patent

warranted hereon all changes and modifications as reasonably and properly

come within the scope of his contribution to the art.

Claims

21We claim as our invention:

1. A non-stretching wound dressing for use with a patient

comprising:

a cover sheet having top and bottom sides,

a thin film sheet formed on the bottom side of the cover sheet, the film

sheet having first and second ends and an adhesive side,

a carrier sheet in adjacent contact with the adhesive side of the thin

film sheet,

a first gripping tab separate from and directly attached to one end of the

thin film sheet and disposed between the film sheet and the carrier sheet

for separating the carrier sheet from the film sheet with the cover sheet

remaining affixed to the film sheet, and

a second gripping tab separate from and directly attached to the top

side of the cover sheet and at one end of the cover sheet so that pulling on the

second gripping tab releases the cover sheet from the film sheet with the film

sheet remaining in place on the patient.

2. The wound dressing as set forth in claim 1 wherein the thin film

sheet has a thickness of about 1.0 mil.

3. The wound dressing as set forth in claim 1 wherein the thin film

sheet has a thickness of less than about 1.0 mil. 22

4. The wound dressing as set forth in claim 3 wherein the thin film

sheet has a thickness of about 0.75 mil.

5. The wound dressing as set forth in claim 4 wherein the thin film

sheet has a thickness of less than about 0.75 mil.

6. The wound dressing as set forth in claim 1 comprising an

intermediate liner separate from and directly attached to the adhesive side of

the film sheet and disposed between the film sheet and the carrier sheet to

promote removal of the film sheet and the carrier sheet, and to permit the

wound dressing to be held by the first gripping tab and intermediate liner

without contacting the thin film sheet.

7. The wound dressing as set forth in claim 6 wherein the second

end of the film sheet comprises a releasable end so that the intermediate liner

may be removed after the film sheet has been attached to the patient.

8. The wound dressing as set forth in claim 7 wherein the

releasable end is formed by perforations.

9. The wound dressing as set forth in claim 7 wherein the

releasable end is formed by scoring.

10. The wound dressing as set forth in claim 1 wherein the first end

of the film sheet comprises a releasable end so that the first gripping tab may

be removed after the film sheet has been attached to the patient.

11. The wound dressing as set forth in claim 10 wherein the

releasable end is formed by perforations. 23

12. The wound dressing as set forth in claim 10 wherein the

releasable end is formed by scoring.

13. The wound dressing as set forth in claim 1 wherein the thin film

sheet is polyurethane.

14. The wound dressing as set forth in claim 1 comprising an

absorbent material in adjacent contact with the adhesive side of the film sheet.

15. The wound dressing as set forth in claim 14 wherein the

absorbent material comprises a medication.

16. A method of use of the wound dressing set forth in claim 1

comprising removing the carrier sheet from the wound dressing,

applying the wound dressing to the patient such that the thin film sheet

binds to the patient,

removing the cover sheet from the thin film sheet using the first

gripping tab thereby leaving the thin film sheet on the patient, and

removing the first gripping tab.

17. A method for making a wound dressing comprising:

forming a thin film sheet on a cover sheet wherein the thin film sheet

has an first side and first and second ends,

adding an adhesive layer to a first side of the film sheet,

adding a first gripping tab to the first end of the thin film sheet, and

adding a carrier sheet to the adhesive side of the thin film sheet. 24

18. The method as set forth in claim 17 comprising adding an

intermediate liner to the second end of the thin film sheet between the thin

film sheet and the carrier sheet.

19. The wound dressing as set forth in claim 17 wherein the thin

film sheet has a thickness of about 1.0 mil.

20. The method as set forth in claim 17 wherein the thin film sheet

has a thickness of less than about 1.0 mil.

21. The wound dressing as set forth in claim 20 wherein the thin

film sheet has a thickness of about 0.75 mil.

22. The wound dressing as set forth in claim 21 wherein the thin

film sheet has a thickness of less than about 0.75 mil.