CN113456353A

CN113456353A - Sterile-packaged non-woven fabric surgical dressing bag and manufacturing method thereof

Info

Publication number: CN113456353A
Application number: CN202110867046.3A
Authority: CN
Inventors: 陈仲璜
Original assignee: Gaoxian Medical Technology Huizhou Co ltd
Current assignee: Gaoxian Medical Technology Huizhou Co ltd
Priority date: 2021-07-29
Filing date: 2021-07-29
Publication date: 2021-10-01

Abstract

The invention discloses an aseptically packaged non-woven fabric surgical dressing bag and a manufacturing method thereof, wherein the non-woven fabric surgical dressing bag comprises a plurality of non-woven fabric dressing sheets and an outer packaging member, and the non-woven fabric dressing sheets are formed into a dressing stack which is sequentially stacked and placed in an unfolding state and then folded at least once to form a folding state; wrapping the outer packaging member outside the folded dressing stack and sealing for sterilization; each non-woven fabric dressing piece comprises a water absorption pad made of spunlace non-woven fabrics and at least one X-ray tracing piece, wherein the at least one X-ray tracing piece is arranged on the water absorption pad. The aseptically-packaged non-woven fabric surgical dressing bag provided by the embodiment of the invention has higher safety and better water absorption. In addition, the automatic processing is convenient to realize, the production speed can be increased by 5 to 10 times, and the manufacturing cost is low.

Description

Sterile-packaged non-woven fabric surgical dressing bag and manufacturing method thereof

Technical Field

The invention relates to medical dressings, in particular to an aseptically packaged non-woven fabric surgical dressing bag and a manufacturing method thereof.

Background

Sterile-packed non-woven surgical dressing packs are generally composed of a sealed outer packaging sterile bag or tray and an inner pack in which a stack of a plurality of surgical dressings is folded and wrapped in a paper or film packaging bag. Note that the inner wrap (if necessary) is intended to protect the sterility of the surgical dressing when it is ready for use on a table in an operating room after removal from the sterile, overwrap sterilization bag. Furthermore, for some common procedures, surgical dressings are typically packaged with other surgical instruments into a sealed and sterilized surgical tray for use as a surgical kit. An inner bag is often required to place the surgical dressing in a tray of a unitized bag along with other surgical components.

Traditionally, the plurality of surgical dressings in a sterile surgical kit are each folded and stacked in a stack, typically 5 or 10 surgical dressings in a stack. The use rate of sterile surgical dressings is very high. The total amount of surgical dressings used per year is more than 1000 billion sheets worldwide.

In surgery, surgical dressings are used primarily to absorb blood and liquid exudates from a surgical site, including the following types of products: abdomen pad, surgical towel with X-ray tracing line. In general, surgical absorbent pads are characterized by: (i) the absorbent pad is made of cotton woven gauze, (ii) in some countries, a barium patch or X-ray tracing lines on or in the dressing for locating the absorbent pad when it is accidentally left in the patient, and (iii) a safety harness for pulling the absorbent pad out of the patient after surgery. Before the water-absorbent dressing is used in surgery, it must be placed in a sterile bag or tray and sealed and sterilized by conventional sterilization methods, such as ethylene oxide, gamma irradiation, electron beam irradiation or steam sterilization.

One of the major safety issues with surgical absorbent dressings is that the dressing may be left in the patient after surgery. The operating room staff counted the number of absorbent dressings in each sterile pack using a sterile pack containing 5 belly pads as an example of a typical dressing counting procedure in surgery to ensure that 5 belly pads were indeed contained therein. If multiple sterile packs are required for the procedure, all packs are opened and counted to ensure 5 dressings per pack. The total number of sheets of belly pad used in the procedure will be equal to (number of packs used x 5 sheets/pack). If the number of pieces in any sterile package does not match, the sterile package is considered a defective sterile package, cannot be put into service and is archived as a complaint to the supplier. After surgery, the used belly pads were collected in a container for dressing counting and counted and compared to the number of belly pads counted before surgery to ensure the same number of dressings counted before and after surgery. If the number of pieces of dressing is not correct before and after the operation, the patient will be subjected to X-ray examination to find the pieces of dressing left in the patient. Statistically, about 0.02% of the dressings are accidentally left in the patient during surgery worldwide, which means that about 5 million surgical dressings are accidentally left in the patient each year.

Currently, there are two main surgical dressings on the market, namely cotton woven gauze dressings and non-woven fabric dressings. Nonwoven dressings are typically made from spunlaced nonwovens of viscose, polyester, bamboo, polypropylene, wood pulp, or cotton fibers. For historical reasons and suitability in wound care and surgery-related applications, cotton gauze dressings are currently used relatively more often than non-woven dressings. However, cotton gauze dressings have a number of disadvantages, including:

(1) since the edges of cotton gauze are open and people frequently come into contact with the dressing during the manufacturing process, much fluff, ends of yarn and other contaminants are typically found in cotton gauze. There is ample evidence that the ends of the yarn and the villi can cause surgical site infection and small vein occlusion.

(2) Most smaller size cotton woven gauze dressings have no selvedge due to high labor costs. Therefore, they cannot be opened for use because of the yarn ends on the edges. For larger, more expensive dressings, such as belly pads, the edges are selvage and sewn so that they can be opened for use.

(3) Due to the larger mesh size of the gauze, the absorbency is relatively low, which means that a greater amount of cotton gauze dressing is required to absorb blood and other exudates.

(4) The manufacturing cost of most cotton woven gauze dressing producing countries in the world is high and tends to rise due to the fact that the manufacturing process comprises a high proportion of labor force and the wage level is rapidly increased.

In contrast, the nonwoven fabric manufactured using the spunlace process has the following advantages compared to cotton woven gauze used for manufacturing surgical dressings:

(1) the molecular structure of the non-woven fabric is more compact, so that the water absorption of the non-woven fabric is much higher than that of cotton woven gauze.

(2) Since there is little fluff and yarn ends, it is less likely to cause infection.

(3) The dressing made of the non-woven fabric can be opened for use, and yarn ends caused by edge opening like gauze do not need to be worried about, so that the dressing is more convenient to use and has more functions.

(4) Can be cut into smaller sizes or different shapes to treat the incision site without concern for any end of the yarn resulting from the opening of the edge like gauze.

(5) Hydroentangling processes provide nonwovens with a wide range of physical properties, and different thicknesses and grammage.

(6) The manufacturing cost is lower due to higher manufacturing automation.

Despite the unique advantages of nonwoven dressings, they are currently used only for simple wound care and treatment. It is still rarely used in hospital surgery due to the following major factors:

(1) historically, cotton gauze dressings have been used in surgery for over 100 years, and it has been very difficult to change the traditional habits of hospitals.

(2) Nonwoven dressings are generally only suitable for small wound care applications and are not suitable for more demanding surgical procedures.

(3) Nonwoven dressings with higher performance and quality standards are not readily available.

To overcome the above obstacles, non-woven fabric surgical dressings must have incomparable advantages over traditional cotton woven gauze surgical dressings. More specifically, the unique properties of nonwoven fabrics should be exploited to design and manufacture surgical dressing packs containing nonwoven fabric dressings, rather than merely following conventional designs and methods. Because these conventional designs and methods were developed to accommodate the properties of cotton gauze, they were not designed based on the superior properties of nonwoven fabrics.

Disclosure of Invention

The present invention is directed to solving, at least to some extent, one of the technical problems in the related art. Therefore, the invention aims to provide an aseptically packaged non-woven fabric surgical dressing bag and a manufacturing method thereof.

To achieve the above objects, in one aspect, a sterile-packed non-woven fabric surgical dressing pack according to an embodiment of the present invention includes:

the non-woven fabric dressing sheets are sequentially stacked and placed in an unfolded state and then folded at least once to form a dressing stack in a folded state;

an outer package wrapped outside the folded stack of dressings and hermetically sterilized;

each non-woven fabric dressing sheet comprises a water absorption pad made of spunlace non-woven fabrics and at least one X-ray tracing piece, and the at least one X-ray tracing piece is arranged on the water absorption pad.

According to the sterile-packaged non-woven fabric surgical dressing bag provided by the embodiment of the invention, the non-woven fabric dressing sheet made of spunlace non-woven fabric has higher safety and better water absorption compared with gauze. In addition, it is a plurality of non-woven fabrics dressing piece stacks the dressing pile that forms fold condition through folding at least once again after placing in proper order under the expansion state, and the extranal packing wraps up the dressing pile of fold condition is outer and sealed sterilization, so, this kind of packaging method, convenient in realizing automated processing, production speed can increase 5 to 10 times, and manufacturing cost reduces as far as possible. Furthermore, when the folded dressing stack is unfolded in use, the nonwoven fabric dressing sheets are unfolded and stacked, and the use is convenient.

According to one embodiment of the present invention, the nonwoven fabric sheet is 2 to 10 sheets.

According to one embodiment of the present invention, the spunlace nonwoven fabric is made of one or more of viscose, polyester, bamboo, polypropylene, wood pulp, and cotton fibers.

According to one embodiment of the invention, the X-ray tracker is attached to the absorbent pad by ultrasonic welding or hot-pressing with a high temperature roller.

According to an embodiment of the present invention, further comprising:

the inner packaging bag is provided with an opening, the folded dressing stack is loaded into the inner packaging bag from the opening, the opening of the inner packaging bag is folded and closed after being loaded into the dressing stack, so that the dressing stack is wrapped in the inner packaging belt to form an inner bag, and the inner bag is loaded into the outer packaging bag and sealed and sterilized.

According to one embodiment of the invention, the outer packaging member is a sterilization bag, the sterilization bag comprises an upper membrane and a lower membrane, the dressing stack is positioned between the upper membrane and the lower membrane, and the edge of the upper membrane is hermetically connected with the edge of the lower membrane; the upper-layer membrane is made of plastic film or paper, and the lower-layer membrane is made of plastic film.

According to one embodiment of the invention, the outer package comprises a tray, in which the stack of dressings is located, and a sealing film, the edge of which is sealingly connected to the tray; wherein, the tray is the plastics material, the seal membrane is plastic film or paper.

According to one embodiment of the invention, the X-ray tracing member is made of a polyvinyl chloride or rubber material containing at least 50% by weight of barium sulfate.

According to one embodiment of the present invention, the development dimensions of the nonwoven fabric dressing sheet are: the width is between 5 and 100cm and the length is between 5 and 100 cm.

According to one embodiment of the invention, each of the nonwoven fabric dressing sheets is provided with a safety retrieval handle made of polypropylene or polyester nonwoven fabric.

According to one embodiment of the present invention, the hydroentangled nonwoven fabric used to make the absorbent pad has a weight of between 35 grams per square meter and 125 grams per square meter and a tensile strength in the machine direction and cross direction of no less than 20 newtons as measured by cutting a 5cm x 10cm test specimen from the fabric and using a tensile tester at a crosshead speed of 20cm per minute.

On the other hand, the method for manufacturing the non-woven fabric surgical dressing bag according to the embodiment of the invention comprises the following steps:

(a) drawing a spunlace nonwoven fabric from each of a plurality of nonwoven fabric rolls, the spunlace nonwoven fabrics lying on top of each other to form a stack of multiple layers of spunlace nonwoven fabrics;

(b) cutting the multi-layer spunlace non-woven fabric to cut a plurality of non-woven fabric dressing sheets with the same size, wherein the non-woven fabric dressing sheets are stacked together;

(c) folding the plurality of non-woven fabric dressing sheets in a stacking mode at least once to form a dressing stack with a smaller size;

(d) the folded dressing stack is packed into an outer package and sealed for sterilization.

In another aspect, a method for manufacturing a non-woven fabric surgical dressing pack according to an embodiment of the present invention includes:

(d) filling the folded dressing stack into an inner packaging bag and wrapping to form an inner bag;

(e) the inner package is packed into an outer package and sealed for sterilization.

According to the method for manufacturing the non-woven fabric surgical dressing bag provided by the embodiment of the invention, automatic processing can be realized, the production speed can be increased by 5-10 times, and the manufacturing cost is reduced as much as possible. Moreover, the non-woven fabric surgical dressing bag prepared by the non-woven fabric dressing sheet prepared by the spunlace non-woven fabric has higher safety and better water absorption compared with gauze. In addition, when the folded dressing stack is unfolded in use, the nonwoven fabric dressing sheets are unfolded and stacked, and the use is convenient.

Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the structures shown in the drawings without creative efforts.

FIG. 1 is a schematic structural view of one embodiment of a non-woven fabric surgical dressing pack of the present invention;

FIG. 2 is an exploded view of one embodiment of a non-woven fabric surgical dressing package of the present invention;

FIG. 3 is a schematic view of a stack of quarter-sized non-woven dressing sheets in a non-woven fabric surgical dressing pack according to the present invention after folding;

FIG. 4 is a schematic view of a stack of one-sixth sized non-woven dressing sheets in a non-woven fabric surgical dressing pack according to the present invention after folding;

FIG. 5 is a schematic view showing the structure of a single nonwoven fabric dressing sheet in the nonwoven fabric surgical dressing pack of the present invention.

The implementation, functional features and advantages of the objects of the present invention will be further explained with reference to the accompanying drawings.

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are exemplary and intended to be illustrative of the present invention and should not be construed as limiting the present invention, and all other embodiments that can be obtained by one skilled in the art based on the embodiments of the present invention without inventive efforts shall fall within the scope of protection of the present invention.

The present invention has been completed based on the following studies and findings of the inventors:

traditionally, surgical dressing bags consist of a pack of individually folded dressings made of cotton woven gauze; wherein, the dressing is formed by wrapping every 5 or 10 pieces of the dressing by hand by using plastic films or paper; this packet, which is wrapped with several pieces of dressing, is then enclosed in the overwrap sterilization bag or tray and sealed for sterilization.

The main object of the present invention is to improve the conventional sterile surgical dressing package from several aspects:

(1) the non-woven sterile surgical dressing bag provided by the invention has higher safety performance, particularly the accuracy of dressing counting, which is a main problem in the use of surgical dressings.

(2) The non-woven surgical dressing should have higher performance than traditional cotton woven gauze dressings.

(3) The sterile surgical dressing bag of the present invention is designed such that the production process is as easy to automate as possible, thereby reducing the manufacturing cost of the sterile surgical dressing bag as much as possible.

The inventors have conducted extensive experiments and studies in order to achieve the above object. Using these findings, the inventors have developed a novel sterile surgical dressing package that meets and exceeds the above objectives. The present invention features that a stack of non-woven fabric dressing sheets is cut from several layers of combined non-woven fabric and drawn from several non-woven fabric rolls to form a stack of several spunlace non-woven fabric dressings, which are laid horizontally on top of each other, and the whole stack of dressing sheets is folded into a required smaller size to form a small stack of folded dressings suitable for packing into outer packing sterilization bags or trays for sterilization, or packing into an inner packing when required. In addition, the whole pile of prefabricated and folded non-woven fabric dressing can also be matched with other components and packed into a sterilization bag or a tray together to form a combined operation bag; wherein the entire surgical kit is sealed and sterilized. The details of the sterile surgical dressing package and the method of producing the same of the present invention are described below.

In the related art, generally, a pack of sterile surgical dressings with X-ray tracing lines of a small size (not more than 20cm X10 cm after being folded) is made of cotton woven gauze, and is produced by using the following process steps:

step 1: the gauze is wound up on the machine.

The production line is filled with a cotton-woven yarn roll with a certain yarn number in the initial part.

Step 2: the X-ray tracing line is connected to the gauze.

When the gauze is pulled to the cutting and folding procedure, connecting the X-ray tracing line with the gauze by a high-temperature roller under certain pressure; or during weaving, the X-ray tracing thread replaces cotton yarn and is woven into gauze by a textile process.

And 3, step 3: cut and folded to make cotton yarn dressings.

And cutting the gauze with the X-ray tracking lines according to the required size and folding the gauze according to the preset layers to prepare the single-piece X-ray tracking surgical dressing.

And 4, step 4: accurately calculating the number of pieces of each package of surgical dressing.

Most sterile surgical dressings contain 5 or 10 pieces of surgical dressing. For most customers in developed countries, the defect level for an acceptable surgical kit with wrong sheet count is typically less than 1ppm (parts per million). To achieve such low defect levels, counting must be done manually and repeated at least 2 times to ensure that the probability of counting errors is less than the 1ppm level (parts per million) required by customers in most developed countries. The cost of the related manual counting procedure can increase the manufacturing cost of the whole dressing by more than 20%.

And 5, step 5: and (6) inner packaging.

The folded surgical dressing sheet is wrapped by an inner packaging bag made of paper or Polyethylene (PE) or polypropylene (PP) film. Because such packaging cannot be done by automated equipment, inner packaging becomes a labor intensive and expensive process.

And 6, step 6: a sterilization bag or tray.

And packaging the dressing inner bag into a sterilization bag or a tray, and sealing the whole sterilization bag or tray.

And 7, step 7: sterilization

Surgical dressings packaged in sealed sterile bags or trays will be sterilized by ethylene oxide, steam, gamma ray or electron beam radiation.

Note that the above process is only used to make small size sterile cotton woven gauze dressings of less than 20cm x 10cm (folded). Larger surgical dressings made of cotton woven gauze are commonly used in larger surgical sites, such as laparotomy. Such surgical dressings are commonly referred to as abdominal pads. For such large procedures, it is desirable that the abdominal pad be made of cotton gauze with selvedges and hems, as any yarn ends or particles at the open edge of the gauze may cause infection at such large surgical sites. Thus, the automated process described above for making small-size conventional cotton yarn dressings is not suitable for producing larger surgical dressings. Instead, the traditional cotton woven gauze abdominal pad is manufactured by hand according to the following process steps:

step 1: the gauze roll is cut into smaller gauze pieces.

A gauze roll with a certain number of weaves is cut into gauze slices according to the size requirement and is used for manufacturing the belly pad.

Step 2: sewing the edges of the gauze slices.

Multiple layers of woven gauze were cut by hand and several layers of gauze were sewn together along the four sides and center to make a single belly pad with multiple layers of gauze.

And 3, step 3: the X-ray traced the connection of the barium plate.

A piece of X-ray tracing barium was sewn manually onto the belly pad.

And 4, step 4: accurately counting the number of belly pads in each bag

Most surgical dressings have 5 belly pads. For most customers in developed countries, the defect level at which the number of abdominal pads per bag counts incorrectly is acceptable is typically less than 1ppm (parts per million). To achieve such a low level of defect acceptance, manual counting must be used at least 2 times. The counting costs associated with manual counting can increase manufacturing costs by more than 20%.

And 5, step 5: and (4) internally packaging.

The folded belly pad is wrapped with a plastic film made of paper or Polyethylene (PE) or polypropylene (PP). The manual packaging process is labor intensive and expensive because such packaging cannot be accomplished by automated equipment.

And 6, step 6: and packaging the inner bag with the dressing into a sterilization bag or a tray.

And 7, step 7: and (5) sterilizing.

Surgical dressings packaged in sterile bags or trays will be sterilized by ethylene oxide, steam, gamma ray or electron beam radiation.

Compared with the manufacturing process of the two cotton woven gauze sterile surgical dressing bags with different sizes, the non-woven fabric sterile surgical dressing bag and the manufacturing method thereof are suitable for sterile surgical dressing bags with different sizes. Furthermore, it should be noted that, in contrast to cotton gauze, it is possible to cut the nonwoven drawn from the nonwoven roll to any size without any problems of unraveling of the ends and edges of the threads. The main advantages of non-woven fabrics over cotton woven gauze are as follows: (a) the non-woven fabric dressing can be opened for use without worrying about the edge being scattered and falling off the yarn end, and the hydro-entangled non-woven fabric can be made into different weights and thicknesses in the production process.

The aseptically packed nonwoven fabric surgical dressing pack and the method of producing the same according to the embodiment of the present invention will be described in detail with reference to the accompanying drawings.

Referring to fig. 1 to 5, the non-woven fabric surgical dressing pack provided according to the embodiment of the present invention includes a plurality of non-woven fabric dressing sheets 10 and an outer package 20.

The plurality of nonwoven fabric dressing sheets 10 are formed into a dressing stack which is sequentially stacked in an unfolded state and then folded at least once to form a folded state. That is, each of the nonwoven fabric dressing sheets 10 is not folded individually, but a plurality of nonwoven fabric dressing sheets 10 are once laminated together in an unfolded state, and the whole of the laminated nonwoven fabric dressing sheets 10 is folded at least once and folded to form a dressing stack having a small size.

Each of the nonwoven fabric webs 10 includes an absorbent pad 101 made of spunlaced nonwoven fabric and at least one X-ray tracing member 102, the at least one X-ray tracing member 102 being disposed on the absorbent pad 101. For gauze, the water absorption pad 101 supported by the spunlace nonwoven fabric has no larger meshes, has stronger water absorption capacity, has no thread ends, is not easy to cause risks such as infection and the like when being applied to an operation, and has higher safety. The X-ray tracing piece 102 is arranged on the water absorption pad 101 and can be developed under X-ray, so that the non-woven fabric applying pieces 10 which are possibly missed are searched, all the non-woven fabric applying pieces 10 are ensured not to be left in the human body, and the safety of the non-woven fabric applying pieces is further improved.

An outer wrapper 20 is wrapped around the folded stack of dressings and sealed for sterilization. Specifically, after a plurality of nonwoven fabric dressing sheets 10 are folded to form a dressing stack, the dressing stack may be hermetically packaged in an outer package 20 and sterilized by ethylene oxide, steam, gamma ray or electron beam radiation.

According to the sterile-packaged non-woven fabric surgical dressing bag provided by the embodiment of the invention, the non-woven fabric dressing sheet 10 made of spunlace non-woven fabric has higher safety and better water absorption compared with gauze. In addition, it is a plurality of non-woven fabrics dressing piece 10 stacks gradually under the expansion state and places the back again through the dressing heap that forms fold condition once folding at least, and outer packing 20 parcel is in the dressing of fold condition is piled up outward and sealed sterilization, so, conveniently in realizing automated processing, production speed can increase 5 to 10 times, and manufacturing cost reduces as far as possible. Further, in use, after the folded dressing stack is unfolded, the nonwoven fabric dressing sheets 10 are laid in an unfolded, stacked state, and are easy to use.

In another embodiment of the present invention, the sterile-packed non-woven fabric surgical dressing pack further comprises an inner packing bag having an opening, the folded stack of dressings is packed into the inner packing bag from the opening, and the opening of the inner packing bag is folded and closed after being packed into the stack of dressings to wrap the stack of dressings in the inner packing bag to form an inner pack, and the inner pack is packed into the outer packing member 20 and sealed and sterilized.

That is to say, in this embodiment, can increase an inner packing bag as required, the folded dressing heap that forms packs into the inner packing bag from the opening, turns over the opening of inner packing bag again and seals, forms an inner bag, packs this inner bag into outer packing 20 at last, seal and the sterilization can, this kind of non-woven fabrics operation dressing package in use, after the inner bag takes out from aseptic outer packing sterilization bag, when waiting to use on placing the desktop of operating room, mesa, can keep apart non-woven fabrics dressing piece 10 with desktop, mesa, ensure the aseptic nature of non-woven fabrics dressing piece 10.

Preferably, the number of non-woven dressing sheets 10 in each non-woven surgical dressing pack is preferably 2 to 10, for example 2 sheets per pack for abdominal pads used in major surgery, 5, 10 sheets per pack for some dressing sheets for absorbing blood, exudates, etc.

It is understood that the spunlace nonwoven fabric is made of one or more of viscose, polyester, bamboo, polypropylene, wood pulp, and cotton fibers, that is, 100% of viscose, polyester, bamboo, polypropylene, wood pulp, or cotton fibers may be used, and of course, two or more of the above fibers may be used in combination according to a certain ratio.

Preferably, the X-ray tracing member 102 is connected to the absorbent pad 101 by ultrasonic welding or hot-pressing with a high-temperature roller, and the ultrasonic welding and the high-temperature hot-pressing welding facilitate automatic processing, improve processing efficiency, and reduce cost.

In one example of the present disclosure, the outer package 20 is a sterilization bag, the sterilization bag includes an upper membrane and a lower membrane, the dressing stack is located between the upper membrane and the lower membrane, and an edge of the upper membrane is hermetically connected to an edge of the lower membrane; the upper-layer membrane is made of plastic film or paper, and the lower-layer membrane is made of plastic film.

That is to say, in this embodiment, outer packing 20 is the sterilization bag, comprises upper diaphragm and lower floor's diaphragm, and the edge sealing connection of upper diaphragm and lower floor's diaphragm, for example heat-pressing seal etc. folded dressing heap is sealed in the space of upper diaphragm and lower floor's diaphragm, and this kind of structure conveniently realizes automated processing.

In another example of the invention, the outer package 20 comprises a tray 201 and a sealing film 202, the dressing stack is located in the tray 201, and the edge of the sealing film 202 is connected with the tray 201 in a sealing way; the tray 201 is made of plastic, and the sealing film 202 is made of plastic film or paper.

That is to say, in this embodiment, the outer package 20 is composed of the tray 201 and the sealing film 202, and the folded dressing stack is placed in the tray 201, and then the sealing film 202 is sealed on the tray 201, and further the dressing stack is sealed in the tray 201, so that the structure is simple, and the automatic production and processing are facilitated.

It will be appreciated that the X-ray tracking member 102 is made of PVC (polyvinyl chloride) or TPE (thermoplastic elastomer) rubber containing at least 50% by weight of barium sulfate.

Preferably, the development dimensions of the nonwoven fabric dressing sheet 10 are: the width is between 5 and 100cm, and the length is between 5 and 100cm, so as to meet various size requirements of the medical dressing.

In one embodiment of the present invention, each of the nonwoven fabric dressing sheets 10 is provided with a safety retrieval handle 103 made of polypropylene or polyester nonwoven fabric, and the safety retrieval handle 103 is used to pull the nonwoven fabric dressing sheet 10 out of the surgical incision by means of a safety retrieval tape after the nonwoven fabric dressing sheet 10 has absorbed blood and exudates.

Advantageously, the weight of the spunlace nonwoven used to manufacture the absorbent pad 101 is between 35 g/m and 125 g/m, and the tensile strength of the spunlace nonwoven in the Machine Direction (MD) and Cross Direction (CD) is not less than 20 newtons, the tensile strength is measured by cutting a 5cm x 10cm test sample from the web and testing the sample with a tensile tester at a crosshead speed of 20cm per minute, the spunlace nonwoven satisfying the above parameters can satisfy both the water absorption and the tensile strength, and thus can satisfy the strength requirement and the water absorption requirement of the dressing in medical applications.

One embodiment of the invention provides a method for manufacturing a non-woven fabric surgical dressing bag, which comprises the following steps:

(a) a spun lace nonwoven is drawn from each of a plurality of nonwoven rolls, and the spun lace nonwoven lies flat on top of each other to form a stack of multiple layers of spun lace nonwoven.

(b) The multi-layered spunlace nonwoven fabric is cut to cut out a plurality of nonwoven fabric dressing sheets of the same size, and the plurality of nonwoven fabric dressing sheets 10 are laminated together.

(c) The stacked plurality of nonwoven fabric dressing sheets 10 are subjected to at least one folding to form a dressing stack of a smaller size.

(d) The folded stack of dressing is loaded into an outer package 20 and sealed for sterilization.

The invention also provides a method for manufacturing the non-woven fabric surgical dressing bag, which comprises the following steps:

(b) cutting the multi-layer spunlace nonwoven fabric to cut a plurality of nonwoven fabric dressing pieces with the same size, wherein the plurality of nonwoven fabric dressing pieces 10 are laminated together;

(c) folding the plurality of non-woven fabric dressing sheets 10 in a stack at least once to form a dressing stack of smaller size;

(e) the inner package is enclosed in an outer package 20 and sealed for sterilization.

Taking a surgical dressing bag containing 5 pieces of non-woven fabric surgical dressings as an example, the main process steps for manufacturing the sterile surgical dressing bag by using the non-woven fabric dressings are as follows:

step 1: 5 rolls of nonwoven fabric were loaded into the machine.

As shown in fig. 2, the front end of the production line had 5 rolls of nonwoven fabric. The nonwoven was pulled from each roll and laid flat together to form a stack of 5 layers of nonwoven.

Step 2: the X-ray trace is attached to the nonwoven.

The X-ray trace is attached to the nonwoven by high temperature rollers or ultrasonic welding as the nonwoven is pulled through the cutting and folding process.

And 3, step 3: cutting and folding to obtain 5 pieces of non-woven fabric dressing.

5 layers of nonwoven drawn from 5 rolls of nonwoven with X-ray tracing are laid flat on top of each other to form a stack of 5 layers of nonwoven. Then the whole pile of 5 layers of non-woven fabrics is cut to form 5 layers of non-woven fabric dressing sheets 10, and the 5 layers of non-woven fabric dressing sheets 10 after being cut are folded in a whole pile (at least once) to prepare 5 pieces of surgical dressings (namely dressing piles) which accord with the preset folding size. Since the above process is carried out by feeding 5 non-woven fabric rolls, and 5 non-woven fabric rolls are elongated, stacked and cut, the number of the non-woven fabric dressing pieces 10 formed after cutting must be 5, in other words, the number of 5 non-woven fabric dressing pieces 10 per bag is accurately included in the process and is 100% accurate, therefore, the product of the present invention does not need the manual counting step required by the traditional cotton gauze dressing.

And 4, step 4: and (4) internally packaging.

The whole folded non-woven fabric dressing (namely the dressing stack) is put into an inner packaging bag made of plastic film or paper, one side of the inner packaging bag is not sealed to form an opening, and a material part (a part where the opening is located) extending out of the inner bag is folded back along the self direction after the non-woven fabric dressing is put into the inner packaging bag to wrap the dressing in the bag to form an inner bag.

And 5, step 5: a sterilization bag or tray 201.

The sealed inner package is packed into the outer package 20 (in a sterilization bag or tray 201) and then sealed for sterilization.

And 6, step 6: and (5) sterilizing.

The nonwoven fabric dressing sheet 10 packed in the sterilization bag or tray 201 will be sterilized by ethylene oxide, steam, gamma ray or electron beam irradiation.

Compared with the traditional method for manufacturing the sterile surgical dressing bag by using the small-size cotton woven gauze medical dressing, the method for manufacturing the non-woven fabric sterile surgical dressing has the following unique advantages: (take a surgical dressing pack containing 5 sheets of non-woven fabric surgical dressings as an example.)

(1) The production speed is at least 5 times faster: the method of the present invention using 5 rolls of nonwoven fabric can produce 5 sheets of nonwoven fabric dressing 10 simultaneously, whereas the conventional method can produce only one dressing at a time.

(2) To ensure accurate counting of the 5 sheets of dressing, no very expensive manual counting is required, since 5 sheets of non-woven dressing are produced each time from 5 rolls of non-woven. The number of 5 dressings per pack was accurately incorporated into the process and was 100% accurate.

(3) Inner package automation can be more easily achieved because a stack of 5 dressings folded together is easier to package into an inner package than a stack of 5 dressings folded (laid flat) together individually.

(4) This results in a significant reduction in manufacturing costs due to the faster production cutting and folding speeds, elimination of expensive hemming and dressing counting steps, and automation of the inner packaging process.

Compared with the traditional medical dressing for manufacturing small-size cotton woven gauze, the sterile surgical dressing bag for manufacturing the non-woven fabric has the advantages. The following describes the unique advantages of the method of making a non-woven surgical dressing of the present invention over conventional methods of making larger sized cotton woven gauze dressings, such as abdominal pads: (take a pack of surgical dressings containing 5 sheets of nonwoven fabric dressing as an example.)

(1) The production speed is at least 10 times faster: the method using 5 rolls of non-woven fabrics can simultaneously produce 5 pieces of non-woven fabric dressing with large size in a short time; the conventional process for manufacturing a large-sized cotton gauze belly pad requires a large amount of manual operations because the sewing process cannot be completed by a machine.

(3) Inner package automation can be more easily achieved because a full stack of 5 dressings folded together is easier to package into one inner package than a stack of 5 dressings folded individually and stacked together.

The non-woven fabric surgical dressing bag disclosed by the invention has the advantages of manufacturing, and also has other advantages superior to the traditional cotton surgical dressing bag:

(1) higher safety performance: the exact number of dressings per stack has been incorporated into the manufacturing process: wherein the number of rolls of nonwoven fabric used in the production line determines the exact number of nonwoven dressings produced and incorporated into each pack of surgical dressings.

(2) The infection rate of the operation part is low. There is ample evidence that the ends and fuzz of cotton gauze can cause surgical site infection. In contrast, the nonwoven fabric surgical dressing is free of fluff and yarn ends.

(3) The use is more convenient: before surgery, large-sized surgical dressings, such as abdominal pads, must be fully opened. The non-woven fabric surgical dressing bag can ensure that all non-woven fabric surgical dressings in the bag can be easily and quickly opened simultaneously when in use. In contrast, cotton surgical dressings require that all the dressings be individually opened one by one when they are opened for use, which is inconvenient and time-consuming.

(4) High water absorption, faster capillary water absorption speed: the water absorption of nonwoven fabrics is generally twice that of cotton gauze. In addition, the nonwoven fabric has a faster water absorption rate due to the capillary action of the fiber structure.

(5) The excellent quality is as follows: the highly automated manufacturing process allows the non-woven fabric surgical dressing pack of the present invention to be more consistent in size and dimensions and less prone to contamination than conventional cotton surgical dressing packs. The gauze dressing is mostly made by hand, so the gauze dressing is more easily polluted in the production process.

(6) Providing a lower price to the end user. The highly automated production process and the faster production speed will result in a significant reduction of the cost of the non-woven surgical dressing pack of the invention, thereby providing a lower price for hospitals and other medical centers.

By using the manufacturing method of the non-woven fabric surgical dressing, various non-woven fabric dressings can be successfully manufactured by using various spunlace material formulas and different non-woven fabric gram weights. The following are 2 tables listing representative X-ray traced line patch (smaller size) and belly pad (larger size) performance from various nonwoven formulations.

TABLE 1 examples of X-ray tracing wire dressing sheets for nonwoven tapes

TABLE 2 non-woven fabric surgical abdominal pad example

In a word, the application discloses a safer, more useful and lower-cost sterile packaging non-woven fabric surgical dressing bag, which is provided with a plurality of pieces of dressing; wherein each dressing comprises an absorbent pad 101 made of spunlace nonwoven fabric and at least one X-ray tracing member 102; wherein each dressing is laid flat on top of each other to form a stack, and the stack is folded together into a smaller sized individual stack of dressings to be packed into an inner bag and then packed into an outer bag or tray 201 for sterilization. The special design of non-woven fabrics dressing package makes production process full automation, its characterized in that: (1) drawing a layer of nonwoven fabric from each of a plurality of rolls of nonwoven fabric, laying flat on top of each other to form a stack of layers of nonwoven fabric, (2) cutting the stack of layers of nonwoven fabric to simultaneously produce a plurality of dressing sheets of the same size, and (3) subsequently folding the cut stack of nonwoven fabric dressing sheets 10 into a smaller size, (4) wrapping the folded dressing with an inner package bag made of plastic film or paper, and (5) internally packaging the packaged dressing in an outer package sterilization bag or tray 201, and then sealing for sterilization.

In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all modifications and equivalents of the present invention, which are made by the contents of the present specification and the accompanying drawings, or directly/indirectly applied to other related technical fields, are included in the scope of the present invention.

Claims

1. An aseptically packaged non-woven fabric surgical dressing pack, comprising:

2. The aseptically packaged nonwoven fabric surgical dressing pack according to claim 1, wherein the nonwoven fabric dressing sheet is 2 to 10 sheets.

3. The aseptically packaged non-woven fabric surgical dressing pack according to claim 1, wherein the spunlace non-woven fabric is made of one or more of viscose, polyester, bamboo, polypropylene, wood pulp, cotton fibers.

4. The aseptically packaged nonwoven fabric surgical dressing pack according to claim 1, wherein the X-ray tracing is attached to the absorbent pad by ultrasonic welding or hot roller thermocompression.

5. The aseptically packaged nonwoven fabric surgical dressing pack according to claim 1, further comprising:

6. The aseptically packaged nonwoven fabric surgical dressing pack according to claim 1, wherein the outer packaging member is a sterilization bag comprising an upper membrane and a lower membrane, the dressing stack is positioned between the upper membrane and the lower membrane, and the edge of the upper membrane is sealingly connected with the edge of the lower membrane; the upper-layer membrane is made of plastic film or paper, and the lower-layer membrane is made of plastic film.

7. An aseptically packaged non-woven fabric surgical dressing pack according to claim 1, wherein the outer package comprises a tray in which the dressing stack is located and a sealing film having an edge sealingly connected to the tray; wherein, the tray is the plastics material, the seal membrane is plastic film or paper.

8. An aseptically packaged non-woven fabric surgical dressing pack according to claim 1, wherein the X-ray tracing member is made of polyvinyl chloride or rubber material containing at least 50% (by weight) barium sulfate.

9. The aseptically packaged non-woven fabric surgical dressing pack according to claim 1, wherein the non-woven fabric dressing sheet has an unfolded size of: the width is between 5 and 100cm and the length is between 5 and 100 cm.

10. An aseptically packaged non-woven fabric surgical dressing pack according to claim 1, wherein each non-woven fabric dressing sheet is provided with a safety retrieval handle made of polypropylene or polyester non-woven fabric.

11. The aseptically packaged nonwoven surgical dressing pack according to claim 1, wherein the weight of the spunlace nonwoven used for making the absorbent pad is between 35 and 125 g/m, and the tensile strength of the spunlace nonwoven in the machine and cross directions is not less than 20 newtons, as measured by cutting a 5cm x 10cm test specimen from the fabric, using a tensile tester at a crosshead speed of 20cm per minute.

12. A method for manufacturing a non-woven fabric surgical dressing bag is characterized by comprising the following steps:

13. A method for manufacturing a non-woven fabric surgical dressing bag is characterized by comprising the following steps: