Patent Description:
Wound dressings are used to manage wound exudate and fluid levels at the wound site and thereby reduce the risk of infection. In order to capture and retain fluid, some wound dressings include an absorbent material, which swells as it becomes saturated with fluid. This swelling absorbent material tends to apply a downward pressure on the wound, as the absorbent material expands within a gap between the wound and the outer layers of the dressing. This downward pressure/force, directed toward the incisional wound, may interfere with closing of the wound, and thereby inhibit the healing process. <CIT> concerns a contoured foam dressing shaped for providing negative pressure to incisions in the breast. <CIT> concerns a wound dressing.

It would be desirable to provide an absorbent dressing that provides apposition forces that tend to close the wound as a result of fluid absorption.

One implementation of the present disclosure is a dressing. The dressing includes an upper cover, a patient interface layer, and an absorbent material. The upper cover is configured to substantially cover the incisional wound. The upper cover includes a drape and a plurality of spines coupled to the drape. The drape includes a first side and a second, wound-facing side. The patient interface layer is coupled to the second side of the drape and includes a plurality of openings that are configured to receive fluid from the incisional wound. The absorbent material is disposed between the second side of the drape and the patient interface layer.

Each of the plurality of spines is configured to be arranged in substantially perpendicular orientation relative to a cut direction of the incisional wound. The plurality of spines are configured to apply appositional forces to the incisional wound in response to the pressure applied to the drape by the absorbent material. For example, the spines may be arranged in aligned pairs that extend at least partially along a length of the drape. Together, the aligned pairs may define two substantially parallel rows of spines. In some instances, the absorbent material may be approximately centered between the two substantially parallel rows of spines and configured to overlie the incisional wound. The orientation of the absorbent material between the two substantially parallel rows of spines and perpendicular to the orientation of each of the plurality of spines may cause a contraction force to be applied to the incisional wound by the dressing in an appositional direction.

In some embodiments, a capacity of the absorbent material varies across the dressing. For example, the capacity of the absorbent material may be greatest in a region that is approximately centered between the two substantially parallel rows of spines.

In some embodiments, the drape is coupled to the patient interface layer along a perimeter of the drape forming a bonded region. The plurality of spines may be coupled to the second side of the upper cover such that each of the plurality of spines is surrounded by the bonded region.

The elasticity of each of the plurality of spines is less than an elasticity of the drape. Each of the plurality of spines may have a thin rectangular shape and may be oriented in a direction that is substantially perpendicular to a longest dimension of the drape. In some instances, each of the plurality of spines is flexible and substantially inelastic (e.g. resistant to stretching).

Another implementation of the present disclosure is a dressing that includes an upper cover, a patient interface layer, and an absorbent material. The upper cover is configured to substantially cover an incisional wound. The upper cover includes a drape having a first side and a second, wound-facing side. The drape defines a plurality of spines. The patient interface layer is coupled to the second side of the drape. The patient interface layer includes a plurality of openings that are configured to receive fluid from the incisional wound. The absorbent material is disposed between the second side of the drape and the patient interface layer.

In some embodiments, the plurality of spines are integrally formed with the drape as a single unitary structure by modifying the drape material properties at the spine locations. For example, the spines may be formed by an ultrasonic welding process applied to the drape.

Another implementation of the present disclosure is a method of making a dressing that includes providing an upper cover having a plurality of spines, providing a patient interface layer having an opening, and providing an absorbent material. The method additionally includes placing the absorbent material onto one of the upper cover and the patient interface layer. The method further includes joining the upper cover and the patient interface layer so that the absorbent material is disposed in between the upper cover and the patient interface layer.

In some embodiments, providing an upper cover includes providing a drape and forming the plurality of spines into the drape by an ultrasonic welding process. The plurality of spines may be arranged in aligned pairs extending at least partially along a length of the upper cover. Together, the aligned pairs may define two substantially parallel rows of spines. In some instances, placing the absorbent material includes joining the absorbent material to the upper cover in a region of the upper cover that is approximately centered between the two substantially parallel rows of spines.

In some embodiments, providing the upper cover includes providing a drape having a first side and a second, wound-facing side, and providing the plurality of spines. Each one of the plurality of spines may include at least one of a felted foam material, a high density foam material, or an injection molded polyurethane material. The method may additionally include joining the plurality of spines to the second side of the drape. In some instances, the patient interface layer may also be coupled to the second side of the drape.

Those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices and/or processes described herein, as defined solely by the claims, will become apparent in the detailed description set forth herein and taken in conjunction with the accompanying drawings.

Referring generally to the Figures, a dressing for treating incisional wounds is shown. The dressing is structured to provide appositional forces to the incisional wound in response to swelling of an absorbent material within the dressing to promote wound closure and facilitate healing. The dressing includes a plurality of flexible but substantially inelastic spines coupled to an upper cover of the dressing. The spines (and upper cover) are separated from the incisional wound by an absorbent material, which is configured to absorb wound exudate from the incisional wound. According to an illustrative embodiment, the spines are arranged in substantially perpendicular orientation relative to a lengthwise cut direction of the incisional wound such that the inelastic spines substantially prevent stretching of the upper cover in a perpendicular direction. As the absorbent material swells outwards, away from the incisional wound, the absorbent material presses against the upper cover. The spines, in response to the applied pressure/force from the absorbent material, lift upward and create an appositional force that pulls the edges of the dressing together (e.g. inward in a perpendicular direction toward the incision) to facilitate wound closure and healing.

In some embodiments, the plurality of spines are arranged in aligned pairs that extend at least partially along a length of the drape. Together, the aligned pairs define two substantially parallel rows of spines, which are configured to be separated from one another by the incisional wound. The absorbent material is approximately centered between the two substantially parallel rows of spines and is configured to overlie the incisional wound. As the dressing absorbs wound exudate, the absorbent swells outwardly from the incisional wound. Among other benefits, the arrangement of spines allows for variation in the closure force provided at different positions along the incisional wound. In other words, the spines are configured to work independently or in unison depending on the level of swelling of the absorbent material and exudate locality to substantially prevent excessive closure forces from being applied to regions of the incisional wound that have already closed or are substantially closed (e.g., regions of the incisional wound where lower levels of wound exudate are produced).

In some embodiments, the spines are integrally formed with the drape as a single unitary structure by modifying the material properties at the spine locations. For example, the spines may be formed into the drape using an ultrasonic welding process, which vibrates the drape material at the desired spine locations to modify the material properties and reduce the elasticity of the drape material. Advantageously, integrally forming the spines into the drape minimizes the number of components used in the dressing and the associated manufacturing complexity associated with placing and/or bonding the spines to the drape. These and other features and advantages of the wound therapy system are described in detail below.

<FIG> shows an advanced wound dressing (AWD) <NUM> applied over an incisional wound, shown as incision <NUM>. The incision <NUM> may be a cut (e.g., surgical incision, laceration, gash, etc.) in a person's skin or other tissue. The incision <NUM> extends longitudinally (e.g., horizontally, left to right as shown in <FIG>) in a cut direction <NUM>. In the illustrative embodiment of <FIG>, the incision <NUM> is an elliptical or fusiform shaped excision, which is wide in the middle and tapered at each end. The dressing <NUM> is disposed centrally over the incision <NUM> and covers the incision <NUM>. In other embodiments, the dressing <NUM> may only cover a portion of the incision <NUM> (e.g., a single leg of the incision, a first portion of an irregularly shaped/non-linear incision, etc.).

Referring to <FIG>, the dressing <NUM> is shown to include an upper cover <NUM>, an absorbent material <NUM>, and a patient interface layer <NUM>. In other embodiments, the dressing <NUM> may include additional, fewer, and/or different components. The upper cover <NUM> extends to an outer edge of the dressing <NUM> such that the upper cover <NUM> substantially covers the incision <NUM> and other parts of the dressing <NUM>. In the illustrative embodiment of <FIG>, the upper cover <NUM> is shown to include a drape <NUM> and a plurality of spines <NUM>. The drape <NUM> includes a first side <NUM> and a second, wound-facing side, shown as second side <NUM>. As shown in <FIG>, each of the plurality of spines <NUM> is integrally formed with the drape <NUM> as a single unitary structure. In other embodiments, the spines <NUM> may be bonded (e.g., adhered) or otherwise coupled to the second side <NUM> of the drape <NUM> using glue, epoxy, or another suitable adhesive product. Among other benefits, integrally forming the spines <NUM> with the drape <NUM> (or adhering spines <NUM> to the second side <NUM> of the drape <NUM>) eliminates the need for additional adhesive products, which might otherwise be required to couple the spines <NUM> to the first side <NUM> of the drape <NUM>, to which no adhesive is generally applied. In other words, the spines <NUM> may be adhered to the drape <NUM> using an adhesive product that is already pre-applied to the second side <NUM> for the purpose of bonding the drape <NUM> to the patient interface layer <NUM>. Moreover, bonding the spines <NUM> to the second side <NUM> of the drape <NUM> shields the spines <NUM> from an environment surrounding the dressing <NUM> and prevents the spines <NUM> from disengaging from the dressing <NUM>. Although there are benefits associated with bonding the spines <NUM> the second side <NUM> of the drape <NUM>, the spines <NUM> may alternatively be coupled to the first side <NUM> of the drape <NUM>, without significantly impacting wound closure performance.

As shown in <FIG>, the absorbent material <NUM> is "sandwiched" or otherwise disposed between the upper cover <NUM> and the patient interface layer <NUM>. Both the absorbent material <NUM> and the upper cover <NUM> are disposed centrally over the patient interface layer <NUM> and the incision <NUM>. The absorbent material <NUM> overlies the incision <NUM> and is configured to absorb and remove wound exudate from the incision <NUM> (e.g., a wound bed, a wound site, etc.) along a length of the incision <NUM> in the cut direction <NUM>. The absorbent material <NUM> may be coupled to at least one of the drape <NUM> or the patient interface layer <NUM> in order to substantially prevent movement of the absorbent material <NUM> relative to the drape <NUM> and the patient interface layer <NUM>.

As shown in <FIG>, the patient interface layer <NUM> is "sandwiched" or otherwise disposed between the absorbent material <NUM> and an outer surface <NUM> of a person's skin. The patient interface layer <NUM> is configured to at least partially seal against the outer surface <NUM> along a portion of the person's skin or tissue that surrounds the incision <NUM>. As shown in <FIG>, the patient interface layer <NUM> includes a plurality of openings <NUM> configured to fluidly couple the absorbent material <NUM> to the incision <NUM>. Fluid passing through the openings <NUM> is received in a cavity <NUM> formed between the patient interface layer <NUM> and the drape <NUM>, where the fluid is absorbed by the absorbent material <NUM>. Dashed arrows <NUM> in <FIG> indicate the flow direction of wound exudate entering the cavity <NUM> from the incision <NUM>. As the absorbent material <NUM> saturates with fluid, the absorbent material expands (e.g., swells, etc.) to fill the cavity <NUM>.

The patient interface layer <NUM> is adhered or otherwise coupled to the drape <NUM> along a perimeter of the patient interface layer <NUM> in order to substantially prevent fluid communication between the cavity <NUM> and an environment surrounding the dressing <NUM>, thus protecting both the wound site and any external surfaces from contamination. The drape <NUM> substantially covers the openings <NUM> in a bonded region <NUM> (see <FIG>) along an outer portion of the patient interface layer <NUM> (e.g., proximate a perimeter of the patient interface layer <NUM>), which improves adhesion of the dressing <NUM> to the outer surface <NUM> of the person's skin. The spines <NUM> and the absorbent material <NUM> are surrounded by the bonded region <NUM>. As shown in <FIG>, the outer dimensions of the drape <NUM> are similar to the outer dimensions of the patient interface layer <NUM> such that an outer edge <NUM> of the drape <NUM> is approximately flush with an outer edge <NUM> of the patient interface layer <NUM>. In other embodiments, the drape <NUM> may extend beyond the outer edge <NUM> of the patient interface layer <NUM>.

Still referring to <FIG>, the dressing <NUM> is configured to provide appositional forces to the incision <NUM> in response to an applied pressure/force from the absorbent material. As shown in <FIG>, each of the plurality of spines <NUM> is arranged to extend in a direction <NUM> that is substantially perpendicular to a longest dimension of the drape <NUM> (substantially perpendicular relative to the cut direction <NUM> of the incision <NUM>) that creates the appositional force. The spines <NUM> are arranged in substantially aligned pairs that are separated from one another in the appositional direction <NUM>. The spines <NUM> thus define two substantially parallel rows that straddle the incision <NUM> and the absorbent material <NUM>. The spacing between spines <NUM> in each pair may differ in various illustrative embodiments. As shown in <FIG>, the spines <NUM> are spaced apart by a distance that is greater than a maximum width <NUM> of the incision <NUM>. Among other benefits, providing a gap between the spines <NUM>, across the incision <NUM>, provides more room for the absorbent material <NUM> to swell, reducing the maximum compressive force applied to the incision <NUM> by the absorbent material <NUM> while also producing the largest possible appositional forces to draw the incision <NUM> together. In other embodiments, the spines <NUM> may extend fully across the incision <NUM>, although in such an arrangement, the therapeutic benefit may not be as significant.

As shown in <FIG>, the aligned pairs of spines <NUM> extend along a portion of the drape <NUM>, in the cut direction <NUM> across the incision <NUM>. Each of the spines <NUM> has a thin rectangular shape whose longest dimension is oriented substantially perpendicular to the cut direction <NUM> of the incision <NUM> (e.g., the appositional direction <NUM>). Each one of the plurality of spines <NUM> is configured to structurally support the drape <NUM> and to reduce the compliance of the drape <NUM> in the appositional direction <NUM>. In other words, each one of the plurality of spines <NUM> is configured to reduce a maximum amount of deformation (e.g., stretch) of the drape <NUM> in the appositional direction <NUM> in response to a force applied to the second side <NUM> of the drape <NUM> by the absorbent material <NUM>.

<FIG> illustrates the uptake of fluid into the dressing <NUM> over a period of time, just after the dressing <NUM> has been applied over the incision <NUM>. As shown in <FIG>, the drape <NUM> is sized to engage with the absorbent material <NUM> in an unsaturated state, before any wound exudate has been absorbed by the absorbent material <NUM>. As shown in <FIG>, fluid (e.g., wound exudate) passing through the patient interface layer <NUM> is absorbed by the absorbent material <NUM>, which swells (e.g., increases in volume) to accommodate the fluid within the cavity <NUM>. The swelling absorbent presses outwardly (e.g., upwardly) from the incision <NUM> toward the second side <NUM> of the drape <NUM>. The orientation of the absorbent material <NUM> relative to the spines <NUM> (e.g., between the two substantially parallel rows of spines <NUM> along the cut direction <NUM>) causes a contraction force in the appositional direction <NUM>. In other words, the spines <NUM> resist deformation of the drape <NUM> in the appositional direction <NUM>, producing a force on the drape <NUM> and the patient interface layer <NUM> that promotes closure of the incision <NUM> locally. As shown in <FIG>, as the absorbent material <NUM> continues to expand, the sides of the dressing <NUM> (e.g., the upper and lower ends of the dressing <NUM> as shown in <FIG>) are pulled together by the appositional forces, which effectively closes the incision <NUM>.

It will be appreciated that as the width of the incision <NUM> decreases, the amount of wound exudate released from the incision <NUM> will also decrease. Hence, the amount of appositional force applied to the incision <NUM> may vary along the cut direction <NUM>. For example, the spines <NUM> may work independently, proximate to a location of a single pair of spines <NUM> as shown in <FIG>, or in unison across the incision <NUM> depending on the amount of swelling of the absorbent material <NUM> and wound exudate locality. Among other benefits, this ability to vary the appositional force in different regions along the cut direction <NUM> prevents excessive closure forces from acting upon regions where the incision <NUM> has already closed (or is substantially closed), thus preventing further deformation of the incision <NUM> (e.g., puckering, etc.) in regions where healing may be progressing more quickly.

Referring to <FIG>, an exploded view of the dressing <NUM> of <FIG> is shown, according to an illustrative embodiment. The upper cover <NUM> is configured to fluidly seal the absorbent material <NUM> within the dressing <NUM> to protect both the incision <NUM> and any external surfaces from contamination. Additionally, the upper cover <NUM> is configured to position the spines <NUM> relative to the absorbent material <NUM>. The upper cover <NUM> includes the drape <NUM> and the plurality of spines <NUM>. The drape <NUM> may be made from a thin high moisture vapor transmission rate (MVTR) adhesive coated polyurethane film such as Inspire <NUM>/<NUM> or another polyurethane or polyethylene film. The drape <NUM> may be at least partially coated in adhesive, for example on the second side <NUM> of the drape <NUM>, in order to bond the drape <NUM> to at least one of the patient interface layer <NUM>, the spines <NUM>, or the absorbent material <NUM>. Alternatively, the drape <NUM> may be pattern coated with adhesive so as to increase the MVTR of the dressing <NUM> (e.g., to improve breathability, to improve the healing effect provided by the dressing <NUM>, to allow at least some of the wound exudate to evaporate from the absorbent material <NUM> once the absorbent material <NUM> becomes saturated with wound exudate, etc.).

The spines <NUM> may be integrally formed or otherwise coupled to the drape <NUM>. In the illustrative embodiment of <FIG>, the spines <NUM> are integrally formed with the drape <NUM> as a single unitary structure by modifying the material properties of the drape <NUM> at the spine <NUM> locations. In particular, the material properties are modified such that an elasticity of each of the plurality of spines <NUM> is less than an elasticity of the drape <NUM>. The change in elasticity of the drape <NUM> at the spine <NUM> locations reduces the compliance of the drape <NUM> in the appositional direction <NUM> (see also <FIG>). In some embodiments, the material properties may be modified by heating the drape <NUM> locally via a suitable forming/heating operation. For example, the spines <NUM> may be formed into the drape <NUM> using an ultrasonic welding process that vibrates the material locally in the area of each spine <NUM>. The ultrasonic welding operation reduces the elasticity of the drape <NUM> in the area of each spine <NUM> without significantly impacting the flexibility of the drape <NUM> (i.e., the spines <NUM> are flexible, but substantially inelastic).

Among other benefits, forming the spines <NUM> into the drape <NUM> reduces the number of manufacturing operations required to make the drape <NUM>. In other embodiments, the spines <NUM> may be formed separately from the drape <NUM> and may be adhered, bonded, or otherwise coupled to the drape <NUM>. For example, the spines <NUM> may be made from a felted foam material or high density foam material. In other embodiments, the spines <NUM> may be made from injection molded polyurethane or another suitably flexible yet substantially inelastic material.

As shown in <FIG>, the dressing <NUM> includes an absorbent material <NUM>, layer, or sheet configured to absorb wound exudate and remove it from the incision <NUM>. According to various illustrative embodiments, the absorbent material <NUM> is made from a superabsorbent laminate such as may be commercially available from Gelok. In other embodiments, the absorbent material <NUM> includes a printed absorbent polymer.

In some embodiments, absorbent material <NUM> may be formed from or otherwise include a superabsorbent polymer in the form of granules. The superabsorbent polymer may include Luquasorb <NUM> or <NUM>, such as may be commercially available from BASF. The granules may be contained in a water-soluble carrier polymer. One example of the water-soluble carrier polymer is polyvinylpyrrolidone (PVP). The superabsorbent polymer and the water-soluble polymer may be formed into a slurry or a suspension using an organic solvent. The organic solvent may include propanone or propanol and may aid in delivery of the absorbent material <NUM> to the drape <NUM>, the patient interface layer <NUM>, or a carrier (e.g., an absorbent foam manifold). In some embodiments, to increase the softness of the superabsorbent granules, a plasticizer may be added to the slurry. In one embodiment, the plasticizer may be water. In some embodiments, the slurry to form the absorbent material <NUM> may have a formulation of <NUM> parts by mass of PVP, <NUM> parts by mass of a superabsorbent polymer, <NUM> part by mass of glycerol, and <NUM> parts by mass of propanone. In some embodiments, to plasticize the granules, <NUM> part to <NUM> parts by mass of water may be added to the slurry mixture. In other embodiments, a water-soluble polymer superabsorbent precursor, such as acrylic acid or <NUM>-acrylamido-<NUM>-methyl-propanesulfonic acid (AMPS), with suitable UV curing additives, may replace the superabsorbent polymer. Such a precursor may be a relatively low viscosity solution and can be printed onto at least one of the drape <NUM>, the patient interface layer <NUM>, or a separate carrier and exposed to UV light to form a soft gel, eliminating the need for a plasticizer. In some embodiments, the water-soluble polymer superabsorbent precursor may be similar to that used for preparing hydrogel coatings.

By way of example, the slurry mixture may be applied to the second side <NUM> of the drape <NUM> to form an absorbent layer. In some embodiments, the slurry may be applied to the drape <NUM> through standard printing methods, such as silk screen printing, gravure printing, or by x-y plotter printing. The absorbent layer may be applied in a variety of different shapes such as circles, squares, hexagons, hoops/halos, stars, crosses, a range of lines, or any combination of shapes. The absorbent layer may be substantially evenly distributed on the drape <NUM> in a line extending along a central position in between the spines <NUM>. In some embodiments, the absorbent material <NUM> may include a flexible plasticized hydrophilic polymer matrix having a substantially continuous internal structure. The absorbent material may also be printed or deposited in a particular pattern intended to suit a particular incision and create a desired degree of appositional force for wound closure.

In some embodiments, the absorbent material <NUM> may include a combination of materials. For example, the absorbent material <NUM> may include a foam carrier (e.g., GRANUFOAM™ or a closed cell foam material) and a superabsorbent polymer printed in key locations along the foam carrier such that a capacity of the absorbent material <NUM> varies across the dressing <NUM> (e.g., varies along the appositional direction <NUM>, etc.). In particular, the superabsorbent polymer may be printed along a line that extends centrally across the foam carrier. In this way, the capacity of the absorbent material <NUM> will be greatest in a region that is approximately centered between the two substantially parallel rows of spines <NUM>. Among other benefits, increasing the capacity of the absorbent material <NUM> locally, directly between the two rows of spines <NUM> may increase the maximum appositional force that can be provided by the dressing <NUM> to the incision <NUM>.

The patient interface layer <NUM> is configured to engage with the patient's skin or tissue to secure the dressing <NUM> in position over the incision <NUM>. As shown in <FIG>, the patient interface layer <NUM> includes an inner surface <NUM>, and an outer, wound-facing surface, shown as outer surface <NUM>. The inner surface <NUM> is coupled to the second side <NUM> of the drape <NUM> proximate to an outer perimeter of the drape <NUM>. The outer surface <NUM> is coupled to the patient's skin and/or wound bed. The patient interface layer <NUM> may be made from a polymer film (e.g., polyurethane film) or a medical textile (e.g., Asahi nylon). The patient interface layer <NUM> may include a suitable low tack adhesive (e.g., silicone or polyurethane gel) to facilitate bonding with the skin surrounding the incision <NUM>. The adhesive may be applied to the outer surface <NUM> of the patient interface layer <NUM> proximate to a perimeter of the patient interface layer <NUM>, or at any other suitable location along the outer surface <NUM>. In some embodiments, the adhesive may be distributed evenly across the outer surface <NUM>.

The patient interface layer <NUM> extends laterally beyond an outer perimeter of the absorbent material <NUM> and the spines <NUM>. In some embodiments, the patient interface layer <NUM> may be substantially the same shape and have the same area as the drape <NUM>. As shown in <FIG>, the patient interface layer <NUM> includes a plurality of openings <NUM> configured to receive fluid from the incision <NUM>. The openings <NUM> include substantially circular holes disposed in a regular pattern across the patient interface layer <NUM>. The size, shape, number, and arrangement of holes may be different in various alternative embodiments. In some embodiments, the openings <NUM> may be sized and/or shaped to collapse across the incision <NUM> in order to minimize the resistance of the patient interface layer <NUM> to the applied appositional forces.

The combination of features shown in the illustrative embodiment of <FIG> should not be considered limiting. Many alternative implementations are possible without departing from the inventive concepts disclosed herein. For example, referring to <FIG>, an advanced wound dressing <NUM> is shown to include a plurality of spines <NUM> that are formed separately from the drape <NUM>, according to an illustrative embodiment. The spines <NUM> are formed together as a single unitary structure, where individual spines <NUM> are interconnected by narrow webs <NUM> or strips of spine material (e.g., felted or high density foams, injection molded polyurethane, etc.). The spines <NUM> are coupled to a second surface of the drape <NUM> as part of a manufacturing operation when making the dressing <NUM>.

Additionally, the dressing <NUM> of <FIG> is shown to include an absorbent layer <NUM> formed from a combination of superabsorbent materials. The absorbent layer <NUM> includes a foam carrier <NUM> and a printed superabsorbent polymer <NUM>. The superabsorbent polymer <NUM> is printed on an upper surface <NUM> of the absorbent layer <NUM>, along a line that is configured to be disposed centrally above an incision. Among other benefits, using a carrier for the superabsorbent polymer improves offloading of compression forces across the incision, while also maximizing the appositional forces that can be produced (as a result of preferential swelling of the absorbent above the incision in the area of the superabsorbent polymer).

Referring to <FIG>, a flow diagram of a method <NUM> of making an advanced wound dressing is shown, according to an illustrative embodiment. The dressing may be the same or similar to the dressing <NUM>, <NUM> of <FIG> and <FIG>, respectively. For simplicity, similar numbering will be used to identify similar components.

At <NUM>, an upper cover is provided. <FIG> show two different methods of providing the upper cover. In the method <NUM> of <FIG>, providing the upper cover (e.g., upper cover <NUM> of <FIG>) includes providing a drape (e.g., drape <NUM>), at <NUM>. Block <NUM> may include applying (e.g., spraying, etc.) an adhesive product to one side of the drape to facilitate bonding with other parts of the dressing <NUM>. The method <NUM> also includes forming a plurality of spines (e.g., spines <NUM>) into the drape by an ultrasonic welding process, at <NUM>. Block <NUM> may include securing a metal fixture over the drape, in areas of the drape where the material properties are to be altered. Block <NUM> may additionally include applying a high frequency vibration to the metal fixture in order to reduce the elasticity of the drape, locally, where the metal fixture contacts the drape.

An alternative method <NUM> of providing the upper cover is shown in <FIG>. The method <NUM> includes providing a drape (e.g., drape <NUM> of <FIG>), at <NUM>, and providing a plurality of spines (e.g., spines <NUM>), at <NUM>. Block <NUM> may include forming the plurality of spines via an injection molding process or another suitable forming operation. At <NUM>, the plurality of spines is joined to a second, wound-facing side of the drape. Block <NUM> may include aligning the spines centrally between outside edges of the drape and adhering the spines to the second side of the drape via glue, epoxy, or another suitable adhesive product.

Returning to <FIG>, the method <NUM> of making the dressing further includes providing a patient interface layer (e.g., patient interface layer <NUM>), at <NUM>, and providing an absorbent material (e.g., absorbent material <NUM>), at <NUM>. Block <NUM> may include perforating a silicone film or sheet to form a plurality of openings, where each opening is configured to receive fluid from an incisional wound. Block <NUM> may include providing a foam carrier (e.g., foam carrier <NUM> of <FIG>) and printing a superabsorbent polymer onto the foam carrier, in a line extending centrally across the foam carrier. Alternatively, or in combination, block <NUM> may include providing a single superabsorbent material, layer, or sheet.

At <NUM>, the absorbent material is placed onto one of the upper cover and the patient interface layer. Block <NUM> may include aligning the adhesive material with a gap in between pairs of adjacent spines <NUM>, in a region of the upper cover that is approximately centered between the two substantially parallel rows of spines (see also <FIG>). Block <NUM> may further include joining (e.g., bonding, adhering, etc.) a superabsorbent polymer or absorbent sheet to at least one of the drape or the patient interface layer (e.g., via a suitable adhesive product).

At <NUM>, the upper cover is joined together with the patient interface layer. Block <NUM> may include laminating (e.g., rolling, etc.) the upper cover onto the patient interface layer such that the absorbent material is "sandwiched" or otherwise disposed between the drape and the patient interface layer. The upper cover (e.g., drape) may be bonded to the patient interface layer in a region surrounding the absorbent material. In other embodiments, the method <NUM> of <FIG> may include additional, fewer, and/or different operations.

Claim 1:
A dressing (<NUM>), comprising:
an upper cover (<NUM>) configured to substantially cover an incisional wound (<NUM>), the upper cover (<NUM>) comprising a drape (<NUM>) having a first side (<NUM>) and a second, wound-facing side (<NUM>), wherein the drape (<NUM>) defines a plurality of spines (<NUM>) or a plurality of spines (<NUM>) is coupled to the drape (<NUM>);
a patient interface layer (<NUM>) coupled to the second side of the drape (<NUM>), the patient interface layer (<NUM>) comprising a plurality of openings (<NUM>) that are configured to receive fluid from the incisional wound (<NUM>); and
an absorbent material (<NUM>) disposed between the second side of the drape (<NUM>) and the patient interface layer (<NUM>),
wherein each of the plurality of spines (<NUM>) is configured to be arranged in substantially perpendicular orientation relative to a cut direction of the incisional wound (<NUM>), and wherein an elasticity of each of the plurality of spines (<NUM>) is less than an elasticity of the drape (<NUM>) such that the plurality of spines (<NUM>) apply appositional forces to the incisional wound (<NUM>) in response to pressure applied to the drape (<NUM>) by the absorbent material (<NUM>).