U.S. patent application number 13/647756 was filed with the patent office on 2013-02-07 for tunnel dressing for use with negative pressure wound therapy system.
This patent application is currently assigned to BOEHRINGER TECHNOLOGIES, L.P.. The applicant listed for this patent is Boehringer Technologies, L.P.. Invention is credited to John Karpowicz, Kevin P. Klocek, Christopher L. Radl.
Application Number | 20130035652 13/647756 |
Document ID | / |
Family ID | 40678868 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130035652 |
Kind Code |
A1 |
Radl; Christopher L. ; et
al. |
February 7, 2013 |
TUNNEL DRESSING FOR USE WITH NEGATIVE PRESSURE WOUND THERAPY
SYSTEM
Abstract
A tunnel dressing for use in treating a tunneling wound using
negative pressure wound therapy. The tunnel dressing includes an
elongate permeable member having a closed distal end for entering
the wound and an open proximal end into which an applicator is
removably disposed for guiding the dressing into the wound. The
tunnel dressing has a support structure adapted to transport wound
exudates away from the wound and to resist compression under
suction. The tunnel dressing also has a wound contact surface
adapted to minimize tissue entanglement to facilitate removal. The
support structure and wound contact surface may be formed from the
same material or from two adjacent layers of different
material.
Inventors: |
Radl; Christopher L.;
(Malvern, PA) ; Klocek; Kevin P.; (Wynnewood,
PA) ; Karpowicz; John; (Chester Springs, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Boehringer Technologies, L.P.; |
Phoenixville |
PA |
US |
|
|
Assignee: |
BOEHRINGER TECHNOLOGIES,
L.P.
Phoenixville
PA
|
Family ID: |
40678868 |
Appl. No.: |
13/647756 |
Filed: |
October 9, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12950002 |
Nov 19, 2010 |
8309787 |
|
|
13647756 |
|
|
|
|
11986941 |
Nov 27, 2007 |
8030534 |
|
|
12950002 |
|
|
|
|
60861358 |
Nov 28, 2006 |
|
|
|
Current U.S.
Class: |
604/319 |
Current CPC
Class: |
A61F 13/00068 20130101;
A61F 13/00995 20130101; A61F 2013/00174 20130101; A61F 2013/00536
20130101; A61F 13/00021 20130101; A61M 1/0088 20130101; A61F
13/00085 20130101; A61F 13/023 20130101; A61F 2013/0054 20130101;
A61F 2013/00825 20130101; A61F 15/005 20130101; A61F 13/00059
20130101; A61M 27/00 20130101; A61F 2013/00302 20130101; Y10T
156/108 20150115; A61F 2013/00561 20130101; A61F 2013/00093
20130101 |
Class at
Publication: |
604/319 |
International
Class: |
A61M 1/00 20060101
A61M001/00 |
Claims
1. A tunnel dressing for use in treating a tunneling wound with
suction comprising an elongate member comprising: a closed distal
end; an opposed proximal end; an elongate cavity opening onto the
proximal end; a permeable inner layer surrounding the cavity, the
inner layer being adapted for transport of wound exudates; and a
permeable outer layer enveloping the inner layer, the outer layer
having a wound contact surface.
2. The tunnel dressing of claim 1, further comprising an elongate
applicator removably disposed within the cavity for guiding the
dressing into the wound.
3. The tunnel dressing of claim 2, wherein the applicator is
adapted to be removed from the cavity while the dressing remains in
place in the wound.
4. (canceled)
5. The tunnel dressing of claim 1, wherein the permeable inner
layer has a structure adapted to maintain at least 75% of its
original volume when subjected to a suction of 75 mm Hg.
6. The tunnel dressing of claim 5, wherein the structure is adapted
to maintain at least 10% of its original volume when subjected to a
suction of 75 mm Hg.
7. The tunnel dressing of claim 1, the permeable inner layer
further comprising multiple structured voids opening onto the
cavity and extending into the inner layer.
8. The tunnel dressing of claim 7, wherein the voids extend into
the inner layer to a depth less than the thickness thereof.
9. The tunnel dressing of claim 8, wherein the structured voids are
dimple voids having a generally circular shape, the dimple voids
comprising sidewalls extending into the support layer and a cap
bridging the sidewalls to form an open cavity.
10. The tunnel dressing of claim 1, wherein the permeable outer
layer comprises a calendared fibrous material forming the wound
contact surface.
11. The tunnel dressing of claim 1, wherein the outer layer is thin
relative to the inner layer.
12. The tunnel dressing of claim 1, wherein at least a portion of
the outer layer is bonded to at least a portion of the inner layer
by heat sealing.
13-66. (canceled)
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of U.S. Provisional
Application No. 60/861,358 filed Nov. 28, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to the treatment of tunneling
wounds using suction or negative pressure wound therapy. More
particularly, the present invention relates to dressings for use in
treating tunneling wounds with suction.
BACKGROUND OF THE INVENTION
[0003] When treating wounds, occasionally wounds are encountered
that are best described as "tunneling" wounds. A tunneling wound is
substantially tunnel-shaped, having an opening at the surface and
extending into the flesh, forming a tunnel that is usually longer,
and sometimes substantially longer, than the width of the opening.
Tunneling wounds can occur by themselves or in combination with a
larger open wound, which may include one or more tunneling wounds.
Because of their depth, tunneling wounds can present significant
risks of infection and can be particularly difficult to heal
completely. Thus, it is desirable to provide treatment that removes
wound exudates (which can support bacterial growth) and promotes
healing of a tunneling wound, including the deepest portions of the
wound. Poor healing in the deepest portions of a wound can lead to
abscesses if the shallower portion of the wound heals first and
closes off the tunnel.
[0004] Suction or vacuum can be applied to a tunneling wound to
promote wound drainage and wound healing. A challenge in treating
tunneling wounds with suction is that it can be difficult to place
a dressing into a deep tunneling wound so that the dressing can
effectively facilitate the removal of wound exudates. Another
challenge in treating tunneling wounds with suction arises because
the application of vacuum causes intimate contact between tissue
and dressing materials, which can cause the tunnel dressing
materials to stick to or become entangled with the wound surface.
Entanglement or sticking of the dressing to the wound tissue
creates a risk that pieces of the dressing can be broken off and
left in the wound when the dressing is removed, and because the
tunneling wound is deep, these pieces are not detectable by the
clinician removing the dressing. Entanglement or sticking of the
dressing to the wound tissue can also cause considerable pain to a
patient when the dressing is removed.
[0005] Accordingly, it would be desirable to provide a tunnel
dressing that can be placed in a tunneling wound so that vacuum can
effectively reach the deepest parts of the wound to remove wound
exudates and to put beneficial strain on the wound tissue. The
dressing should be easy to insert into a tunneling wound.
Additionally, the dressing should be easily removable from the
tunneling wound without excessive entanglement or sticking to the
wound tissue, and strong enough so that it can be removed from the
wound in one piece without breaking and leaving small or large
pieces in the wound. A tunnel dressing that allows vacuum to
effectively reach the deepest parts of the wound also enables
fluids to be removed from the deepest parts of the wound, which
helps to avoid entrapment of fluid that can lead to an abscess.
[0006] Various dressings for use in tunneling wounds during suction
therapy have been devised in the prior art. Some dressings employ
generally solid rubber (e.g., silicone) or plastic devices having
distinct holes or channels formed or cut into them for the purpose
of transporting fluids. Other dressings employ a tube-like device
having holes extending through the tube walls. There are several
disadvantages to these types of devices. Because these devices are
constructed from an impermeable material having discrete holes,
vacuum cannot be applied uniformly and is thus concentrated on a
relatively small portion of the wound surface. Further, the
material from which these devices are formed is relatively
inflexible, making it difficult and uncomfortable for the patient
when the devices are inserted into a wound. Still further, the
presence of discrete holes provides space into which large
protrusions of tissue can grow, which can cause considerable pain
when the devices are removed from a wound.
[0007] Still other vacuum dressings employ foam having an open cell
structure for transporting fluids. When used for tunneling wounds,
such dressings are supplied as a rectangular piece of foam that
must be cut by a clinician to match the estimated size of the
tunneling wound. A disadvantage of using foam is that foam lacks
any significant tensile strength and thus is prone to break when
being extracted from the wound, leaving pieces behind within the
tunneling wound cavity. Moreover, it is not possible to readily
discern when a piece of foam has broken off and remains lodged in
the wound, because a torn or cut edge of the foam appears the same
as a broken edge. The problem with foam is so significant and well
known that after a clinician has cut a piece of foam to size, he or
she is trained to tug on the foam piece to try to ascertain if it
is strong enough prior to insertion. A further disadvantage of foam
is that the foam lacks the stiffness required to push it into many
tunneling wounds, so that a clinician often must use a long Q-tip
or other ad hoc device to help push the foam dressing into the
wound.
[0008] Yet other vacuum dressings utilize a tube interconnecting
between a suction source at one end and a pad disposed at the
opposite end, the tube otherwise having no holes or apertures to
communicate vacuum to the wound. In use, the device is placed with
the pad deep inside the wound and the tube partly disposed within
the wound and extending out from the wound. Any unfilled space
surrounding the tube within the wound may be filled with gauze.
Numerous disadvantages result from this type of arrangement. Often
a tunneling wound is too narrow to allow the pad (with the
connected tube) to be placed deep within the wound and to
subsequently completely surround the tube with gauze. Further, the
device effectively applies vacuum forces only to the wound surface
that is in contact with the pad or is in contact with whatever
gauze can be packed in around the tube. Thus, the applied suction
will generally be able to evacuate exudates from a wound but will
be unable to apply suction forces to tissue that is in contact with
only the tube. Still further, when the pad is made from foam, all
of the problems discussed above with regard to foam dressings may
result. In addition, the pad can become detached from the end of
the tube and left in the wound when the device is withdrawn. Also,
there is no mechanism for introducing the device into a deep tunnel
wound other than by pushing on the flexible tube.
SUMMARY OF THE INVENTION
[0009] A tunnel dressing is provided for use in treating a
tunneling wound with suction, the tunnel dressing comprising an
elongate permeable member having a distal end adapted for entering
the wound and an opposed proximal end. The permeable member further
has an outer surface and a cavity opening onto the outer surface.
An applicator can further be provided having a distal portion
disposed within the cavity and a proximal portion extending out of
the permeable member, the applicator being adapted to guide the
dressing into the wound. The cavity can open onto the outer surface
at the proximal end of the permeable member, or the cavity can open
onto the outer surface at a location between the distal end and the
proximal end of the permeable member.
[0010] A tunnel dressing is provided for use in treating a
tunneling wound with suction comprising an elongate permeable
member having a closed distal end adapted for entering the wound,
an opposed proximal end, an outer wound contact surface, and an
elongate cavity opening onto the proximal end and extending into
the permeable member toward the distal end. The cavity is adapted
to receive an applicator for guiding the dressing into the wound.
The tunnel dressing can further comprise an applicator having a
distal portion adapted to be removably received in the cavity and a
proximal portion extending outwardly from the permeable member.
[0011] A tunnel dressing is provided for use in a treating a
tunneling wound with suction comprising an elongate permeable
member having a closed distal end adapted for entering the wound,
an opposed closed proximal end, an outer wound contact surface, and
a cavity opening onto the wound contact surface at a location
between the distal end and the proximal end. The cavity is adapted
to receive an applicator for guiding the, dressing into the wound.
The tunnel dressing can further comprise an applicator having a
distal portion adapted to be removably received in the cavity and a
proximal portion extending outwardly from the permeable member.
[0012] A tunnel dressing is provided for use in treating a
tunneling wound with suction comprising an elongate member. The
elongate member comprises a closed distal end, an opposed proximal
end, an elongate cavity opening onto the proximal end, a permeable
inner layer surrounding the cavity, the inner layer being adapted
for transport of wound exudates, and a permeable outer layer
enveloping the inner layer. The outer layer has a wound contact
surface. The tunnel dressing can further comprise an elongate
applicator removably disposed within the cavity for guiding the
dressing into the wound.
[0013] A method is provided for treating a tunneling wound with
suction. The method comprises providing a tunnel dressing
comprising an elongate permeable member having a closed distal end
adapted for entering the wound and an opposed proximal end, the
permeable member further having an outer surface and a cavity
opening onto the outer surface, the tunnel dressing further
comprising an applicator having a distal portion disposed within
the cavity and a proximal portion extending out of the permeable
member, the applicator being adapted to guide the dressing into the
wound; inserting the tunnel dressing into the tunneling wound by
grasping the proximal portion of the applicator and applying gentle
force to push the distal end of the dressing into the wound until
increased resistance is detected; placing a wound cover over the
tunnel dressing and adhering the wound cover to skin surrounding
the wound to form a substantially air-tight seal, the wound cover
being adapted to communicate suction via a conduit from a suction
source to the wound; and applying suction from the suction source
to the wound.
[0014] A system for treating a tunneling wound with suction is
provided. The system comprises a tunnel dressing comprising an
elongate permeable member having a distal end adapted for entering
the wound and an opposed proximal end, the permeable member further
having an outer surface and a cavity opening onto the outer
surface; and an applicator having a distal portion disposed within
the cavity and a proximal portion extending out of the permeable
member, the applicator being adapted to guide the dressing into the
wound; a suction source; a wound cover adapted to form a
substantially air-tight seal over the wound dressing by adhering to
skin surrounding the wound; and a conduit having an end operatively
associated with the wound cover and an opposite end operatively
associated with the suction pump, to communicate suction to the
wound.
[0015] A method of making a tunnel dressing for use in treating a
tunneling wound with suction is provided, comprising forming a
stack comprising two layers of a first fibrous material sheet
sandwiched between two layers of a second fibrous material sheet,
the sheets having edges; ultrasonically welding the four layers
together to form a unitary piece; trimming excess material away
from the unitary piece between the weld and the edges of the sheets
to form an article having three sealed edges and an un-sealed edge;
and inverting the article to form the tunnel dressing having an
internal weld.
[0016] A tunnel dressing for treating a wound with suction
comprising a generally elongate permeable member is provided. The
permeable member comprises a distal end; a proximal end; a cohesive
permeable outer wound contact surface; and a permeable internal
core. The wound contact surface is adapted to transport wound
exudates from the wound tissue to the internal core and is
generally free of protrusions that could become embedded in the
wound tissue and left behind in the wound tissue when the tunnel
dressing is removed. The core has interconnecting interstices
extending from the distal end to the proximal end for transporting
wound exudates along the elongate member, at least some of the
interstices being resistant to complete collapse under the
compressive forces of therapeutic suction and in the presence of
wound exudates such the core remains capable of transporting fluid.
The tunnel dressing has sufficient tensile strength to resist
breakage during removal from the wound after exposure to
therapeutic suction and wound exudates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a tunnel dressing.
[0018] FIG. 2 is a cross-sectional view of an embodiment of the
tunnel dressing of FIG. 1 taken through section 2-2.
[0019] FIG. 3A is a cross-sectional view of an exemplary open wound
having a tunneling wound portion into which a tunnel dressing would
be inserted.
[0020] FIG. 3B is a cross-sectional view of an exemplary tunneling
wound into which a tunnel dressing would be inserted.
[0021] FIG. 4 is a cross-sectional view showing a tunnel dressing
as in FIG. 1 inserted into a tunneling wound as in FIG. 3B.
[0022] FIG. 5 is a cross-sectional view of an embodiment of the
tunnel dressing of FIG. 1 taken through section 2-2.
[0023] FIG. 6 is a partial perspective cross-sectional view of the
tunnel dressing of FIG. 5.
[0024] FIG. 7A is a cross-sectional view showing a tunnel dressing
as in FIG. 1 inserted into a tunneling wound as in FIG. 3A, wherein
suction is applied to the wound.
[0025] FIG. 7B is a cross-sectional view showing a tunnel dressing
as in FIG. 1 inserted into a tunneling wound as in FIG. 3B, wherein
suction is applied to the wound.
[0026] FIG. 8 is a perspective view of a tunnel dressing.
[0027] FIG. 9 is a perspective view of a tunnel dressing.
[0028] FIG. 10 is a perspective view illustrating a method of
making a tunnel dressing.
DESCRIPTION OF THE INVENTION
[0029] Referring to the drawings, where like numerals identify like
elements, there is shown in FIGS. 1 and 2 a tunnel dressing 10 for
treating a tunneling wound with suction according to an embodiment
of the invention. The tunnel dressing 10 has a generally elongate
shape to provide for insertion of the tunnel dressing 10 into a
tunneling wound, such as shown in FIGS. 3A and 3B. The tunnel
dressing 10 preferably has a closed distal end 46 and an open
proximal end 48, and sides 47 spanning between the ends 46, 48,
such that the closed end 46 can be inserted into a tunneling wound
with the open end 48 protruding outwardly from the wound. The
tunnel dressing 10 can have a generally round or circular
cross-section, as shown in FIG. 1, or can have a more oblong or
ovalized cross-section, depending on the shape of the tunneling
wound into which the tunnel dressing 10 will be inserted. The
tunnel dressing 10 can be used, as illustrated for example in FIGS.
7A and 7B, for treating a tunneling wound with suction as part of a
negative pressure wound therapy system 70.
[0030] The tunnel dressing 10 comprises an outer sheath layer 12
contacting an inner core or support layer 14 along at least a
portion of an interface 22. The tunnel dressing 10 has a distal end
46 and a proximal end 48. The sheath 12 and the layer 14 can be
bonded to each other along their respective edges or across a
portion of, or all of the interface 22. Alternatively, the sheath
layer 12 can be slipped over the support layer 14 as a cover and
need not be attached thereto. The outer sheath 12 has a wound
contact surface 20 and the inner layer 14 has an inner surface 24.
The outer sheath 12 is thin relative to the inner layer 14, the
inner layer 14 provides structural support to the tunnel dressing
10 and the outer sheath 12 providing a suitable wound contact
surface 20. In an embodiment, the support layer 14 is about 0.080
inches thick and the sheath 12 is about 0.003 inches thick.
[0031] The outer sheath 12 readily transports fluid therethrough
from the wound to the support layer 14 and preferably has
sufficient structural integrity so as to not leave fibers behind in
the wound. The wound contact surface 20 is cohesive and is
sufficiently smooth to allow for easy insertion and removal by
minimizing the adherence of new tissue thereto. The inner layer 14
provides structural support to the sheath 12 and comprises a
permeable fibrous structure to allow for transport of exudates
lengthwise along the dressing 10 (i.e., in the direction from the
distal end 46 to the proximal end 48) and out of the wound when
suction is applied by a negative pressure wound therapy system 70.
Because the inner layer 14 may include fibers that are only loosely
coupled together, the outer sheath 12 serves to retain loose fibers
so they are not left in the wound when the dressing 10 is
removed.
[0032] The sheath 12 is made from a permeable material adapted to
allow wound exudates to be transported therethrough, such that when
the wound is subjected to suction, wound exudates can be drawn away
from the wound surface. Under suction, exudates are drawn through
the sheath 12 and into the layer 14, and then through the layer 14
towards the proximal end 48 of the tunnel dressing 10. The sheath
12 is preferably made from a fibrous material having a high
structural integrity, such as nonwoven polyester, with tightly
coupled fibers that are not prone to shed into the wound. The wound
contact surface 20 of the sheath 12 has a relatively smooth
structure as can be achieved by calendaring the material of the
sheath 12. The fibers of the sheath 12 are preferably long
continuous fibers that can be bonded together with heat.
[0033] The contact surface 20 is substantially without very large
voids or discontinuities (i.e., voids greater than an order of
magnitude larger than the average interstitial space between
adjacent fibers), in order to minimize the tendency for large
protrusions of wound tissue to become entangled in the tunnel
dressing 10. Rather, the contact surface 20 comprises a large
number of small openings or interstitial spaces between fibers
which enables good fluid transport. The small interstitial spaces
between fibers in the contact surface 20 also minimize tissue
entanglement and prevent any loose fibers from the layer 14 from
becoming embedded in the wound tissue and left behind in the wound.
Further, the fibers of the sheath 12 generally do not protrude or
terminate beyond the wound contact surface 20, thus minimize the
possibility that fibers can be embedded in wound tissue or left
behind in wound tissue when the dressing 10 is removed after the
application of suction therapy.
[0034] The permeable nature of such a fibrous material of the
sheath 12 allows for application of vacuum to more of the wound
surface than can be obtained with dressings having discrete holes
or channels. The polyester fibers generally do not absorb fluids,
meaning that they do not swell when subjected to moisture but
instead allow liquid to be conducted along their surface and
through the fibrous material under the force of applied suction.
One such material is sold by Ahlstrom Corp. as Hollytex 3257, a
spunbond polyester sheet having a highly calendared surface. Other
such materials having slightly larger interstitial spaces are
Hollytex 3256 and Hollytex 3249. Other similar or equivalent
materials can be used. The sheath 12 is preferably made from a
sheet of material, the sheet being formed by heat sealing or
welding into a sheath-like shape with a closed end onto the support
layer 14, as shown in FIGS. 1 and 2. The heat sealing or welding
process provides additional strength to the sheath 12, and thus to
the dressing 10, which eliminates or substantially reduces the risk
that a portion of the tunnel dressing 10 can break off and be left
in a tunneling wound.
[0035] The core or support layer 14 is made from a permeable
material having a structure that imparts compression resistance to
enable the layer 14, and thus the tunnel dressing 10, to resist
collapse or compression under the force of therapeutic suction,
such as that applied during negative pressure wound therapy. A
negative pressure wound therapy system can apply negative pressures
to a wound in the range of about 5 mm Hg to about 500 mm Hg,
preferably in the range of about 25 mm Hg to about 200 mm Hg, and
most preferably in the range of about 30 mm Hg to about 75 mm
Hg.
[0036] The layer 14 is also adapted to transport wound exudates
that are drawn from the wound through the sheath 12 into the layer
14, so that the exudates can be removed from the dressing 10 by
suction applied at the end 48 of the dressing 10 by a negative
pressure wound therapy system 70. The layer 14 is preferably made
from a fibrous material such as nonwoven polyester felt. During the
felting process, fibers become oriented in multiple directions,
which improves the compression resistance of the layer 14. The
fibrous material of the layer 14 preferably has interconnected
interstices throughout, at least some of the interstices resisting
complete collapse under the compressive forces resulting from
negative pressure wound therapy and in the presence of wound
exudates so that the interstices remain capable of transporting
fluid through the dressing. As with the fibers used to form the
sheath 12, the polyester fibers of the support layer 14 generally
do not absorb fluids, meaning that they do not swell when subjected
to moisture but instead allow liquid to be conducted along their
surface and through the fibrous material under the force of applied
suction. One such material is felt made from polyester fibers, the
material having a thickness of about 0.080 inches and a basis
weight of 5 ounces per square yard.
[0037] In an embodiment, the tunnel dressing 10 is about 6 inches
long and about 0.25 inches in diameter (i.e., a length to diameter
ratio of about 24), although the dressing 10 can be made in a wide
range of lengths, diameters, and length/diameter combinations. The
fluid transport properties of the support layer 14 enable the
withdrawal of exudates by suction from very deep wounds. The layer
14 is preferably made from a sheet of material, the sheet being
formed by heat sealing into a sheath-like shape with a closed end
as shown in FIGS. 1 and 2 such that the inner surface 24 of the
layer 14 faces itself and forms a cavity 18 within the dressing
10.
[0038] The dressing 10 comprising the support layer 14 and the
sheath 12 can be made from layered sheets of material, as depicted
in FIG. 10. Two sheets 412a and 412b of material for forming the
sheath 12 (e.g., spunbond polyester) are sandwiched between two
sheets 414a and 414b of material for forming the support layer 14
(e.g., polyester felt) to form a stack 490 of layered materials.
Next, the four layers are preferably ultrasonically welded together
along a generally U-shaped weld 480 forming essentially three sides
of a rectangle, leaving a non-welded portion forming essentially a
fourth side of the rectangle. The corners of the rectangle can be
more rounded or less rounded depending on the desired configuration
of the dressing 10.
[0039] It is contemplated that the four layers could be formed by
layering a sheet of material 412 on top of a sheet of material 414
and folding the two layers over on themselves along a fold line, so
that the stack only need be welded along a generally L-shaped weld
line forming two sides of a rectangle, the third closed side being
formed by the fold line. It is further contemplated that the stack
could be welded along a generally box-shaped weld line forming
essentially all four sides of a rectangle. Then, the weld along a
portion forming essentially one side of the rectangle can be cut
off to create a non-welded opening. Alternatively, all four welds
can be left in place and an opening can be cut through one of the
layers 414a and one of the layers 412a to enable access to a cavity
formed between the layers 412a and 412b.
[0040] Next, the layers of material 414a, 412a, 412b, and 414b are
cut around the weld 480 to remove the excess material between the
weld 480 and the edges of the stack 490, as well as any excess
material between the end of a U-shaped or L-shaped weld 480 and the
edges of the stack 490 at the non-welded opening. The remaining
article has two layers of support material 414a and 414b on the
outside surrounding two layers of sheath material 412a and 414b, a
weld 480 on essentially two or three edges of the article that is
relatively hard and jagged compared with the layers of material,
and an opening at one end of the article where the layers are not
welded together. Finally, the article is inverted or turned inside
out to form a tunnel dressing 10 having an internal weld 480, an
outer sheath 12 of spunbonded material, an inner core or support
layer 14 of felt, and a cavity 18 disposed within the inner support
layer 14 (i.e., between the sheets 414a and 414b). Cavities also
exist between each of the sheets 414a/414b and its corresponding
adjacent sheet 412a/412b.
[0041] The resultant tunnel dressing 10 has a closed distal end 446
and an open proximal end 448, with the weld 480 extending
internally along the length of the dressing from the closed end 446
to the open end 448. The weld 480 imparts additional tensile
strength to the dressing so that after the application of suction
to a wound having the dressing 10 therein, the dressing 10 can be
removed without breaking and without leaving any remnants of the
dressing 10 in the wound cavity. The weld 480 also extends
internally along the distal closed end 446 of the dressing 10,
imparting additional strength to the closed end 446 to inhibit, or
to assist in preventing, the applicator rod 16 from pushing through
the closed end 446 when the dressing 10 is being inserted into a
wound.
[0042] The tunnel dressing 10 is preferably inserted into a
tunneling wound using a semi-flexible applicator rod 16 removably
disposed within the cavity 18. Exemplary wounds are illustrated in
FIGS. 3A and 3B. The applicator rod 16 is preferably made from a
relatively thin piece of material that is sufficiently rigid to
transmit force along its length as required to gently push and
guide the dressing 10 into the wound, yet is sufficiently flexible
to follow the contours of the tunneling wound as the dressing 10 is
being inserted. The rod 16 is preferably less flexible than the
dressing 10. The rod 16 can comprise plastic, wood, metal, paper,
and/or other suitable material.
[0043] The rod 16 engages the far end of the tunnel dressing 10 so
that when a clinician pushes on the rod 16, force is transmitted to
the distal end 46 of the tunnel dressing 10, the end 46 thereby
pulling the remainder of the tunnel dressing 10 into the tunneling
wound. In a tunneling wound 62 such as shown in FIGS. 3B and 7B,
the tunnel dressing 10 can be used alone to dress the wound cavity
for treatment of the wound 62 with suction. In an open wound 50
including a tunneling portion 52 such as shown in FIGS. 3A and 7A,
the tunnel dressing 10 can be used in combination with a wound
packing 80 such that the tunnel dressing 10 dresses the tunneling
portion 52 and the wound packing 80 dresses the remainder of the
wound cavity 50 for treatment of the wound 50 with suction. Many
wound packings 80 are known in the art, including packings
disclosed in U.S. patent application Ser. No. 10/981,119, filed on
Nov. 4, 2004 and commonly assigned with the present
application.
[0044] Providing the tunnel dressing 10 in a sheath-like shape
having a closed distal end 46 is advantageous compared with
attempting to push a flat sheet into a tunneling wound using a rod.
In particular, the dressing 10 can easily be guided into a deep
tunneling wound with only a small amount of force, the smooth
material of the contact surface 20 on the tip 46, in conjunction
with the contact surface 20 on the sides 47, guiding the dressing
10 as the rod 16 is gently pushed inwardly into the wound. Thus,
pain is minimized and the dressing 10 can be placed as far as
desired into the wound.
[0045] For clarity of description, the process of inserting the
tunnel dressing 10 is generally described herein with reference to
a tunneling wound 60 as illustrated in FIGS. 3B, 4, and 7B, it
being understood that the description applies similarly to an open
wound 50 having a tunneling portion 52 as illustrated in FIGS. 3A
and 7A. A tunneling wound 62 in a tissue surface 68 can be defined
by walls 66 and a bottom end 64. Alternatively, a tunneling wound
can be defined as a wound 50 in a tissue surface 58 having a
tunneling portion 52 defined by walls 56 and a bottom end 54.
[0046] To insert the tunnel dressing 10 into a tunneling wound 62,
a clinician grasps the rod 16 at a proximal end 17 protruding from
the open end 48 of the dressing 10. A dressing 10 should be
selected that is somewhat longer than the anticipated depth of the
wound 62 so that a portion of the dressing 10 remains protruding
from the wound 62 after insertion. The protruding portion of the
dressing 10 can be readily grasped for removal. The clinician
gently guides the tunnel dressing 10 into the tunneling wound 62 by
applying light force along the length of the rod 16. The rod 16,
the sheath 12, and the layer 14 are sufficiently flexible to follow
the countours of the walls 66 of the tunneling wound 62 as the
dressing 10 is inserted thereinto. When the clinician feels
increased resistance indicating that the dressing 10 is reaching
the end 64 of the wound 62, the clinician can gently withdraw the
rod 16, leaving the dressing 10 in place within the wound 62.
[0047] Withdrawal of the rod 16 leaves a small elongate cavity 18
within the dressing 10 extending from the open end 48 to near the
closed end 46. The cavity 18 serves a functional purpose during use
of the dressing 10, in addition to providing a receptacle for the
applicator rod 16 during insertion of the dressing 10. The cavity
18 has less resistance to collapse than the permeable material of
the support layer 14 or of the sheath 12, and therefore enables the
tunnel dressing 10 to be compacted somewhat in width as the wound
cavity 62 is drawn together under applied suction without hampering
the fluid transport capacity of the layer 14 or the sheath 12 of
the dressing 10.
[0048] In order to encourage tissue growth in the end 64 of the
wound 62 when suction is applied to the dressing 10, the clinician
preferably partially withdraws the dressing 10 slightly away from
the wound end 64 before suction is applied by grasping a portion of
the dressing protruding from the wound 62 and pulling gently
outwardly. The preferred position of the tunnel dressing 10 within
the wound 62 is shown schematically in FIG. 4, the dressing 10
being fully inserted into the wound 62 and then partially withdrawn
slightly to leave a space 90 for tissue growth in the wound end 64.
The space 90 is preferably about 1 centimeter from the wound end 64
to the dressing 10, recognizing that a larger or smaller space may
be desired depending on the depth, width, exudate rate, and other
characteristics of the wound 62. Once the dressing 10 is in place,
if a larger portion of the dressing 10 is protruding from the wound
62 than desired or than needed for later removal of the dressing
10, the excess dressing 10 may be cut off to preferably leave a
small protruding portion.
[0049] After the tunnel dressing 10 has been installed into the
wound 62, a conventional vacuum or negative pressure wound therapy
system can be used to apply suction to the wound. Such a negative
pressure wound therapy system 70 is shown generally in FIGS. 7A and
7B, the system comprising a suction source 78, a wound cover 72
having an adhesive coating 74 on one side for adhering to skin
surrounding a wound, and a conduit 76. The conduit 76 has an end
operatively associated with the wound cover 72 and an opposite end
operatively associated with the suction source 78 for communicating
suction from the suction source 78 to the wound 62 beneath the
wound cover 72. Non-exhaustive examples of applicable vacuum or
negative pressure wound therapy systems are described in detail,
for example, in U.S. patent application Ser. No. 11/786,475, filed
on Apr. 12, 2007 and in U.S. patent application Ser. No.
11/181,128, filed on Jul. 14, 2005, both commonly assigned with the
present application. The suction source 78 can comprise a
stationary suction system such as those commonly found in
hospitals, or a portable pump or bellows or other equivalent
mechanism for providing and delivering a therapeutic level of
suction to the wound.
[0050] For a tunneling wound 62 of the type shown in FIG. 3B, a
wound cover 72 can be placed directly over the tunnel dressing 10,
as shown in FIG. 7B. The cover 72 comprises a semi-permeable
material that is generally air-tight but allows vapor and/or
moisture to be transported therethrough. The cover 72 is adhered to
the skin 68 surrounding the wound by the adhesive coating 74 to
provide a substantially air-tight seal over the wound. For a wound
50 of the type shown in FIG. 3A, the wound 50 having a tunneling
portion 52, a packing 80 is preferably used to fill the open cavity
of the wound 50 before applying the cover 72 by adhering the
adhesive layer 74 to the skin 58 surrounding the wound 50.
[0051] When suction is applied by the negative pressure wound
therapy system 70 to a wound 62 having the tunnel dressing 10
inserted thereinto, the suction is transmitted through the
permeable material of the layer 14 and the sheath 12 to the wound
tissue along the sides 66 and end 64 of the wound 62. The wound
tissue is drawn against the wound contact surface 20, causing
compression force on the dressing 10. In absorbing the compression
force, the cavity 18 collapses inwardly, allowing at least a
portion of the interstitial spaces within the support layer 14 and
sheath 12 to remain open so that the suction can draw wound
exudates out of the wound 62 through the wound cover 72 and into
the conduit 76. Once the cavity 18 has collapsed, the support layer
14 can still be subjected to compressive forces due to the applied
suction. The support layer is capable of resisting compression to
maintain its fluid transport properties.
[0052] Preferably, the support layer 14 retains at least 10% of its
original uncompressed volume when subjected to a suction of 75 mm
Hg. In an embodiment, prior to the application of suction, the
support layer 14 comprises about 5% polyester fibers and about 95%
void space. In an embodiment, after application of a suction of 75
mm Hg, the support layer 14 retains about 75% of its original
volume (so that the compressed layer 14, by volume, is about 7%
fibers and 93% void space). To maintain adequate ability to
transport wound exudates and provide suction to the wound tissue,
the support layer preferably maintains at least about an equal
amount of void space to the amount of fiber space, or about 10% of
its original uncompressed volume (so that the compressed layer 14,
by volume, is about 50% fibers and 50% void space).
[0053] Depending on the negative pressure wound therapy regimen,
suction can be applied continuously or intermittently for periods
ranging from a few hours to several days. When the time comes to
remove or change the tunnel dressing 10, the clinician first
removes the wound cover 72 and any packing 80 that may have been
used. Then, grasping the portion of the dressing 10 protruding from
the wound 62, the clinician gently pulls the dressing 10 to extract
it from the tunnel wound 62. The structure of the dressing 10 is
sufficiently strong that it retains its tensile strength even after
being subjected to wound exudates and suction, such that the
dressing does not tear or come apart as it is being removed. As
discussed above with regard to FIG. 10 and a method of making the
dressing 400, a weld 480 is formed extending along the inside of
the dressing 400 from the distal end 446 to the proximal end 448.
Similarly, in the tunnel dressing 10 as shown in FIGS. 1, 2, 4, 7A,
and 7B, a weld (not shown) extends along the inside of the dressing
10 from the distal end 46 to the proximal end 48, the weld
providing additional tensile strength to the dressing 10 to prevent
tearing or breaking apart of the dressing 10 upon removal from the
wound 62.
[0054] The tunnel dressing 10 can further be provided with
regularly spaced markings 42 along the length of the sides 47
(i.e., from near the closed distal end 46 to near the open proximal
end 48), as shown in FIG. 1. The markings 42 provide a visual
indication of how deep the wound is, and can be used to determine
the progress of a wound as it heals. The markings 42 also provide a
measure to indicate how far the dressing 10 is partially withdrawn
after it has been fully inserted, to leave sufficient space 90 for
tissue growth in the wound end 64. The markings 42 can be made
using a biocompatible ink, a series of slight depressions or
protrusions from the surface 20 of the dressing 10, or other
similar regularly repeated visual indicator.
[0055] The tunnel dressing 10 can also be provided with a visual
marking 44 at the tip of the closed end 46, to provide assurance
that the entire dressing 10 has been withdrawn. If a clinician
withdraws the dressing 10 and the visual marking 44 is not present,
the clinician is alerted that a part of the dressing 10 may remain
within the wound cavity. The marking 44 is preferably made using a
biocompatible ink, an embossing, or other similar identifiable
visual indicator.
[0056] The support layer 14 of the tunnel dressing 10 can include
structural features to enable the dressing 10 to resist compression
when subjected to vacuum. Resisting compression enables good
transport of wound exudates away from the wound surface 66 and out
of the tunnel wound 62. In an embodiment, the layer 14 comprises
randomly disposed fibers. In another embodiment, as shown in
cross-section in FIG. 5, a support layer 30 comprises multiple
structured voids or cavities 32 opening onto the inner surface 24
and extending into the layer 30. The structured voids 32 provide
structural support to enable the layer 30 to resist compression
under vacuum to both maintain the surface 20 of the dressing 10 in
contact with the wound surface 66 and to keep open at least a
portion of the interstitial spaces within the fibrous material of
the layer 30 to provide for good fluid transport.
[0057] Each void 32 comprises a cavity opening onto the inner
surface 24 and extending a depth into the layer 30. The voids 32
may extend through the entire thickness of the layer 30, or may
extending only to a depth that is less than the thickness of the
layer 30. Each void 32 comprises sidewalls 34 extending generally
perpendicularly to the surface 24, a cap 36 bridging the sidewalls
to form a cavity within the void 32, and an opening 38 on the
surface 24. The voids 32 are spaced apart in the material so that
the openings 38 are correspondingly spaced apart on the surface 24.
The width of the openings 38 in the surface 24 is preferably
greater than about 0.1 mm and less than about 10 mm, more
preferably between about 0.5 mm and about 5 mm, and most preferably
about 2 mm. The depth of the voids 32, measured from the opening 38
in the surface 24 to the cap 36, is preferably greater than about
0.1 mm when suction is applied, more preferably between about 0.2
mm and 5 mm, and most preferably about 1.5 mm. The voids 32 are
preferably dimple voids 32 that are generally circular in shape, as
shown in FIG. 6, but can also be oblong, oval, square, triangular,
channels, or other geometric shape capable of providing structural
rigidity. The voids 32 can be formed into the layer 30 by several
methods, including by heat stamping or vacuum forming, by applying
molten material directly to a mold as in meltblowing, or by mixing
fibers with an adhesive and spraying the mix onto a textured
surface.
[0058] FIG. 8 shows another embodiment of a tunnel dressing 210 for
treating a wound with suction. The tunnel dressing 210 is made from
a permeable material 212 preferably having a fibrous structure
similar to the support layer 14 in the tunnel dressing 10 of FIG.
1. The tunnel dressing 210 has a closed proximal end 248 and a
closed distal end 246 spanned by at least a sidewall 247. The
distal end 246 is adapted to enter a wound, so that when the
dressing 210 is inserted into a tunneling wound, the distal end 246
is inserted first and leads the way into the depths of the wound.
The tunnel dressing 210 further has an internal cavity 218 and a
wound contact surface 220. The internal cavity 218 opens onto the
wound contact surface 220 at an opening 250 disposed in the
sidewall 247 between the proximal end 248 and the distal end 246.
The cavity 218 extends at least from the opening 250 to near the
distal end 246. The internal cavity 218 may also extend from the
opening 250 toward the proximal end 248. An applicator rod 216
having a proximal portion 217 and a distal portion (not shown) can
be used to guide the dressing 210 into a wound, the distal portion
being removably disposed within the cavity 218 and the proximal
portion 217 extending out from the tunnel dressing 210. After the
dressing 210 is inserted into the wound, the rod 216 can be removed
without disturbing the dressing 210 in the wound.
[0059] When the dressing 210 is formed from a fibrous material 212
such as polyester felt, the material 212 can be thermally seared
along the outer wound contact surface 220 to minimize fiber
shedding. Alternatively, the dressing 210 can be formed from a
fibrous material 212 comprising a combination of polyester fibers
and biocomponent fibers. Bicomponent fibers are fibers that have a
core of one material and a sheath of a slightly different material.
The material of the sheath preferably has a lower melting
temperature than the material of the core so that products made
from such fibers can be heated to a temperature that melts the
sheath but not the core. The molten sheath material then locks or
fuses the fibers together when cooled so that there is less
shedding of fibers. In an embodiment, the dressing 210 could be
formed from 85% standard polyester fiber and 15% bicomponent fibers
having a polyester core with a 250.degree. C. melting temperature
and a copolyester sheath with a melting point ranging between about
110.degree. C. and about 220.degree. C. After it is formed into the
desired shape, the material 212 of the dressing 210 could then be
heated so that the sheath material melts to create a contact
surface 220 less likely to shed fibers into the wound.
[0060] FIG. 9 shows another embodiment of a tunnel dressing 310 for
treating a wound with suction. The tunnel dressing 310 is made from
a permeable material 312 preferably having a fibrous structure
similar to the support layer 14 in the tunnel dressing 10 of FIG.
1. The tunnel dressing 310 has an open proximal end 348 and a
closed distal end 346 adapted to enter a wound, so that the when
the dressing 310 is inserted into a tunneling wound, the distal end
346 is inserted first and leads the way into the depths of the
wound. The tunnel dressing 310 further includes an internal cavity
318 and a wound contact surface 320. The internal cavity 318 opens
onto the proximal end 348 of the dressing 310 and extends within
the dressing 310 to near the distal end 346. An applicator rod 16
having a proximal portion 17 and a distal portion (not shown) can
be used to guide the dressing 310 into a wound, the distal portion
being removably disposed within the cavity 318 and the proximal
portion 17 extending out from the tunnel dressing 310. After the
dressing 310 is inserted into the wound, the rod 16 can be removed
without disturbing the dressing 310 in the wound. The wound contact
surface 320 of the dressing 310 can be prepared in any of the
manners previously discussed with regard to the wound contact
surface 220 of the dressing 210 shown in FIG. 8.
[0061] While the invention has been disclosed with reference to
certain preferred embodiments, numerous modifications, alterations,
and changes to the described embodiments are possible without
departing from the sphere and scope of the invention, as defined in
the appended claims and equivalents thereof. Accordingly, it is
intended that the invention not be limited to the described
embodiments, but that it have the full scope defined by the
language of the following claims.
* * * * *