Nonwoven Material Transfer System for Medical Implants and Filtration Devices

A system and method for transferring and bonding nonwoven material members to substrates in medical implant and filtration device applications, leveraging the core technology of the original patent to expand into new industries.

The original patent disclosed a method for transferring nonwoven material members for use in absorbent articles. However, the existing method has limitations in terms of its applicability to other industries. The new inventive concept addresses this limitation by adapting the core technology to transfer and bond nonwoven material members to substrates in medical implant and filtration device applications, where precise control over material placement and bonding is crucial.

The new inventive concept comprises a system and method for transferring one or more cut-out nonwoven material members to substrates in medical implant and filtration device applications. The system includes a cutting station and a vacuum transfer roll with a vacuum port pattern unit matching the outline shape of the one or more cut-out nonwoven material members. The method involves transferring the cut-out nonwoven material members using the vacuum transfer roll and bonding them to the substrate. The nonwoven material members can be Carded Air Through Bonded, Carded Spunlace, or Carded Needle punched nonwoven material members.

The new inventive concept introduces a novel application of the original patent's core technology to medical implant and filtration device industries, which was not considered in the original patent. The inventive step lies in the adaptation of the vacuum transfer roll and vacuum port pattern unit to precisely control material placement and bonding in these new industries.

Alternative embodiments of the inventive concept could include different vacuum port pattern units, modified cutting stations, or additional bonding mechanisms to accommodate various substrate materials and geometries. Variations could also include the use of different nonwoven material members or substrates, or the integration of sensors and monitoring systems to ensure quality control.

The new inventive concept has significant commercial potential in the medical implant and filtration device industries, where precise control over material placement and bonding is critical. The system and method could be used in the manufacturing of implantable devices, such as surgical meshes, or in the production of filtration devices, such as air or water filters. The target market includes medical device manufacturers, filtration device manufacturers, and research institutions.