Method for manufacturing contoured and laminated materials

A method for manufacturing wound dressings comprising the steps of:

• providing a continuous supply of a first outer layer having a support layer and a backing layer, the support layer being of a material sufficient to protect the backing layer and having a release coating;
• providing a continuous supply of a second outer layer having a second release coating;
• providing a subject layer of a material having predetermined malleability and a first surface and a second surface;
• contouring and attaching the first outer layer to the first surface of the subject layer and attaching the second outer layer to the second surface of the subject layer, and to form a first intermediate product at a contouring and laminating station, the contouring and laminating station comprising a contouring and laminating roller and a second roller, the contouring and laminating roller positioned opposite the second roller so as to drive the first intermediate product by co-operating rotational action of the contouring and laminating roller and the second roller thereby precluding the need for a driving station;
• removing the support layer from the backing film on the first intermediate product at a delaminating station to form a second intermediate product comprising the subject layer interposed between the backing layer and the second outer layer;
• and
• cutting the second intermediate product into discrete end products by carrying the second intermediate product through a cutting station in a predetermined registered and timed relationship.