Manufacturing method of thumb adduction orthosis

Abstract

The invention discloses a manufacturing method of a thumb adduction orthosis, and relates to the technical field of orthosis. The manufacturing method of the thumb adduction orthosis comprises the following steps: S1, acquiring a hand model: firstly, acquiring a palm model by using a gypsum bandage and a gypsum pouring mold, scanning an acquired three-dimensional data file by using a 3D scanner, acquiring a shell part of the orthosis by using computer three-dimensional data processing software, and acquiring a hand model for the acquired shell of the orthosis; and the abduction force is increased to thicken the jaw of the shell part of the orthosis, so that the frontal view is improved. According to the thumb adduction orthosis, the thermoplastic polyurethane material is adopted for injection molding, on one hand, the probability that the thumb adduction orthosis deforms in all directions due to wearing is reduced, and on the other hand, the thermoplastic polyurethane material is high in durability, good in environmental protection performance, good in air permeability, light in weight, high in strength and suitable for being worn on the hand of a child; and the skin of children cannot be hurt.

Description

Technical Field

[0001] The invention belongs to the technical field of orthoses, and in particular relates to a method for manufacturing a thumb adduction orthosis. Background Art

[0002] The thumb adduction orthosis is a medical device used to treat thumb adduction deformity, a common condition that causes the thumb to bend inward, usually due to improper stretching of muscles or ligaments. This deformity may affect hand functions, such as grasping objects or performing fine hand movements. The thumb adduction orthosis helps the thumb return to its normal position and range of motion by applying appropriate pressure or tension, thereby improving hand function.

[0003] For mild cases of thumb adduction deformity, a thumb adduction brace is usually able to effectively correct the deformity and help patients regain hand function. For moderate or severe deformities, a thumb adduction brace may need to be used in conjunction with other treatments (such as physical therapy or surgery) to achieve better results. In addition, a thumb adduction brace can also be used to prevent the occurrence of thumb deformity. For example, for people who need to use computers or perform manual activities for a long time, wearing a thumb adduction brace can reduce hand fatigue and joint pain.

[0004] In practical applications, thumb adduction orthosis has achieved remarkable results. For example, thumb adduction is a common training difficulty in children with cerebral palsy, but the use of thumb adduction orthosis has greatly improved the abnormal grasping posture of children with moderate to severe thumb adduction.

[0005] However, when traditional thumb adduction orthoses are actually manufactured, due to the different sizes and thicknesses of thumbs of different human groups, it is difficult to closely match the thumbs of different patients when using the thumb adduction orthosis for correction operations, resulting in a series of problems that affect the correction effect, such as correction misalignment, which is prone to occur during the subsequent thumb correction process. Summary of the invention

[0006] The object of the present invention is to provide a method for manufacturing a thumb adduction orthosis to solve the problems raised in the above background technology.

[0007] In order to achieve the above-mentioned invention object, the present invention adopts the following technical scheme:

[0008] The present invention provides a method for manufacturing a thumb adduction orthosis, comprising the following steps:

[0009] S1. Obtaining a hand model: first obtain a palm model using plaster bandage and plaster casting, scan the three-dimensional data file obtained by a 3D scanner, and use computer three-dimensional data processing software to obtain the outer shell of the orthosis. For the obtained orthosis outer shell, increase the outward force to thicken the base of the orthosis outer shell to improve the front view;

[0010] S2. Selection of orthosis materials: Considering the comfort and ductility of the orthosis during use, the obtained orthosis shell part is prepared by thermoplastic polyurethane material, and the molded orthosis is cooled and solidified at room temperature to obtain a molded thumb adduction orthosis;

[0011] S3. Assembly of parts: For the molded thumb adduction orthosis, assemble Velcro. The Velcro should be made of elastic material to increase the traction on the radial side of the thumb.

[0012] As a preferred embodiment of the present invention, in S1, the three-dimensional data of the orthosis obtained by scanning with a 3D scanner is analyzed using DasViewer software.

[0013] The DasViewer software uses CDEM as the computing core and GPU parallel acceleration to quickly simulate the three-dimensional data of the orthosis.

[0014] As a preferred embodiment of the present invention, in S3, the Velcro is made of nylon.

[0015] As a preferred embodiment of the present invention, in S2, the injection molding of the orthosis shell portion comprises the following steps:

[0016] S4. Raw material preparation: The components of thermoplastic polyurethane material include polycaprolactone, plasticizer, anti-adhesive agent, inorganic filler and masterbatch. The specific proportions are: 60-100 parts of polycaprolactone, 0.5 parts of plasticizer, 0.55 parts of anti-adhesive agent, 0.4-0.45 parts of inorganic filler, and 0.4 parts of masterbatch;

[0017] S5, mixing and melting: After various raw materials are mixed in proportion, they are melted and plasticized through an extruder to form a uniform melt. In this process, the temperature is 65°C-120°C, the pressure is 34MPa-37MPa, and the time is 1-3 minutes to ensure the stability and consistency of the thermoplastic polyurethane material melt. The extruder is a flat extruder, which crushes the thermoplastic polyurethane material through the rotation of a single screw and converts the thermoplastic polyurethane material into a plastic sheet;

[0018] S6, Shell molding: Use a flat heater to heat the material to 60-70℃, soften it and shape it.

[0019] As a preferred embodiment of the present invention, in S5, the extruder is a flat extruder, and the thermoplastic polyurethane material is crushed by the rotation of a single screw, and the thermoplastic polyurethane material is converted into a plastic sheet.

[0020] Compared with the prior art, the present invention provides a method for manufacturing a thumb adduction orthosis, in which carbon quantum dots are prepared using glucose and dodecylamine, a microcapsule wall material solution is prepared using PLGA as a wall material, and then the carbon quantum dots are wrapped with microcapsules to form a carbon quantum dot oil-displacing agent with a sustained-release function.

[0021] One or more of the above technical solutions have the following beneficial effects:

[0022] 1. The thumb adduction orthosis manufactured by the present invention can quickly detect and analyze the palm data of different patients by scanning the three-dimensional data of the patient's palm with a 3D scanner and analyzing the three-dimensional data of the palm with DasViewer software, so that the data analysis of the palm parts of different patients can be performed more quickly. At the same time, the molded thumb adduction orthosis is injection molded by thermoplastic polyurethane material. On the one hand, it reduces the probability of deformation of the thumb adduction orthosis in all directions due to wearing. On the other hand, the thermoplastic polyurethane material has strong durability, good environmental performance, good air permeability, light weight, high strength, suitable for wearing on children's hands, and will not cause damage to children's skin;

[0023] 2. The thumb adduction orthosis manufactured by the present invention is thickened at the base of the thumb in order to increase the abduction force of the orthosis, so as to ensure that the contact part between the orthosis and the base of the thumb has sufficient strength, and will not cause the risk of the orthosis breaking due to the patient's long-term action (pressing and bending the thumb). At the same time, the part of the orthosis away from the thumb is equipped with elastic Velcro, which can increase the traction force on the radial side of the thumb, further improving the convenience of wearing and removing the orthosis. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0025] Figure 1 It is a front view of the three-dimensional data model of the hand of the present invention;

[0026] Figure 2 is a three-dimensional image of the patient's arm and palm of the present invention;

[0027] Figure 3 is a rear view of the outer shell portion of the orthosis of the present invention;

[0028] Figure 4is a side view of the outer shell portion of the orthosis of the present invention;

[0029] Figure 5 This is a front view of the orthosis shell of the present invention after the base of the thumb is thickened;

[0030] Figure 6 is a side view of the orthosis shell of the present invention after the base of the thumb is thickened;

[0031] Figure 7 is a front view of the orthosis of the present invention assembled with Velcro;

[0032] Figure 8 is a structural diagram of the palm after the orthosis of the present invention is fitted;

[0033] Fig. 9 It is a structural diagram of the orthosis of the present invention in combination with the back of the palm. DETAILED DESCRIPTION

[0034] In order to enable those skilled in the art to understand the characteristics and effects of the present invention, the following is a general description and definition of the terms and expressions mentioned in the specification and claims. Unless otherwise specified, all technical and scientific terms used in the text are the common meanings understood by those skilled in the art for the present invention. In the event of a conflict, the definition in this specification shall prevail.

[0035] The theories or mechanisms described and disclosed herein, whether correct or incorrect, should not limit the scope of the present invention in any way, that is, the present invention can be implemented without being limited by any specific theory or mechanism.

[0036] Herein, all features such as values, quantities, contents and concentrations defined in the form of numerical ranges or percentage ranges are for simplicity and convenience only. Accordingly, the description of numerical ranges or percentage ranges should be considered to have included and specifically disclosed all possible secondary ranges and individual values ​​within the range (including integers and fractions).

[0037] In this document, unless otherwise specified, “includes,” “including,” “contains,” “has,” or similar terms cover the meanings of “consisting of” and “mainly consisting of,” for example, “A includes a” covers the meanings of “A includes a and other” and “A only includes a.”

[0038] In this document, in order to make the description concise, not all possible combinations of various technical features in various embodiments or examples are described. Therefore, as long as there is no contradiction in the combination of these technical features, the various technical features in various embodiments or examples can be combined arbitrarily, and all possible combinations should be considered to be within the scope of this specification.

[0039] The present invention will be further described below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms fall within the scope limited by the appended claims of the application equally.

[0040] The following examples use conventional instruments and equipment in the art. The experimental methods in the following examples where specific conditions are not specified are usually carried out under conventional conditions or under conditions recommended by the manufacturer. The various raw materials used in the following examples are conventional commercial products unless otherwise specified, and their specifications are conventional specifications in the art. In the specification of the present invention and the following examples, unless otherwise specified, "%" means weight percentage, "part" means weight part, and ratio means weight ratio.

[0041] See also Figure 1-Figure 9 The present invention discloses a method for manufacturing a thumb adduction orthosis, comprising the following steps:

[0042] S1. Obtaining a hand model: first obtain a palm model using plaster bandage and plaster casting, obtain a three-dimensional data file by scanning with a 3D scanner, and use computer three-dimensional data processing software to obtain the outer shell of the orthosis. For the obtained orthosis outer shell and the three-dimensional data of the orthosis obtained by scanning with a 3D scanner, use DasViewer software to analyze the three-dimensional data of the orthosis. DasViewer software uses CDEM as the computing core and GPU parallel acceleration to quickly simulate the three-dimensional data of the orthosis, increase the outward force to thicken the base of the orthosis outer shell to improve the front view;

[0043] S2. Selection of orthosis materials: Considering the comfort and ductility of the orthosis during use, the obtained orthosis shell part is prepared by thermoplastic polyurethane material, and the molded orthosis is cooled and solidified at room temperature to obtain a molded thumb adduction orthosis;

[0044] S3. Assembly of parts: For the molded thumb adduction orthosis, assemble Velcro. The Velcro should be made of elastic material to increase the traction on the radial side of the thumb. The Velcro is made of nylon.

[0045] The injection molding of the orthosis shell part includes the following steps:

[0046] S4. Raw material preparation: The components of thermoplastic polyurethane material include polycaprolactone, plasticizer, anti-adhesive agent, inorganic filler and masterbatch. The specific proportions are: 60-100 parts of polycaprolactone, 0.5 parts of plasticizer, 0.55 parts of anti-adhesive agent, 0.4-0.45 parts of inorganic filler, and 0.4 parts of masterbatch;

[0047] S5, mixing and melting: After various raw materials are mixed in proportion, they are melted and plasticized through an extruder to form a uniform melt. In this process, the temperature is 65°C-120°C, the pressure is 34MPa-37MPa, and the time is 1-3 minutes to ensure the stability and consistency of the thermoplastic polyurethane material melt;

[0048] S6. Shell molding: Use a flat heater to heat the material to 60-70°C to soften it and then shape it. The shaped material is operated for 3-5 minutes at room temperature. Adjust the angle and shape it evenly until it cools and sets.

[0049] In the present invention, the workflow of DasViewer software is:

[0050] 1) Data loading and processing: DasViewer supports import and export of multiple data formats, including local and online 3D models, images, point clouds, vector data, etc. Users can quickly open the model with one-click operation, and support the simultaneous opening of multi-path and multi-origin data, greatly improving work efficiency.

[0051] 2) Model cropping: Users can crop models by adding configuration files and cropping tools. The specific steps include preparing data, generating configuration files, importing cropping surfaces, opening cropping tools, selecting cropping surfaces or hand-drawing cropping surfaces, saving cropped data, and reorganizing.

[0052] 3) Model browsing and editing: DasViewer provides a variety of display modes, such as texture display, white model display, texture + wireframe display, etc. Users can choose the appropriate display mode according to their needs. In addition, the software also supports dual-screen comparison, accuracy inspection, light source adjustment, 3D measurement and other functions, which facilitates users to perform data analysis and visualization operations.

[0053] 4) Path roaming and high-definition video output: Users can customize the roaming path and output high-definition video (3D data and images of the orthosis shell) according to the flight route.

[0054] 5) Tile management and annotation tools: DasViewer also provides tile management functions, and users can select, delete or export specific tiles (orthosis shell 3D data and images) as needed.

[0055] In the present invention, the following process is adopted for the extrusion operation of the thermoplastic polyurethane material:

[0056] 1) Adding materials: Add the thermoplastic polyurethane material to the feed port of the extruder.

[0057] 2) Heating: The barrel of the extruder is heated to a suitable temperature through a heating system. The temperature of the thermoplastic polyurethane material is usually 65°C-120°C, at which time the thermoplastic polyurethane material reaches a molten state.

[0058] 3) Melting: Due to heating, the thermoplastic polyurethane material gradually melts in the barrel and becomes a viscous molten state. At this time, the screw in the extruder starts to rotate, pushing the molten thermoplastic polyurethane material to the front end.

[0059] 4) Extrusion: At the front end of the barrel, the extruder is equipped with a die head. The molten thermoplastic polyurethane material is pushed into the die head by the rotation of the screw. The shape of the die head determines the shape of the extruded product.

[0060] 5) Cooling: After extrusion from the die, the thermoplastic polyurethane molded product enters the cooling zone. Cooling is usually achieved by cooling water or cold air, and the thermoplastic polyurethane molded product is solidified by rapid cooling.

[0061] 6) Cutting: After the thermoplastic polyurethane molded product is cooled, the length is customized through a cutting device. After cutting, it is moved to a flat heater for final molding.

[0062] Without limitation, any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent substitutions or changes according to the technical solution and inventive concept of the present invention, should be covered by the protection scope of the present invention.

Claims

1. A method for manufacturing a thumb adduction orthosis, characterized in that: The following steps are involved: S1. Obtaining a hand model: first obtain a palm model using plaster bandage and plaster casting, scan the three-dimensional data file obtained by a 3D scanner, and use computer three-dimensional data processing software to obtain the outer shell of the orthosis. For the obtained orthosis outer shell, increase the outward force to thicken the base of the orthosis outer shell to improve the front view; S2. Selection of orthosis materials: Considering the comfort and ductility of the orthosis during use, the obtained orthosis shell part is prepared by thermoplastic polyurethane material, and the molded orthosis is cooled and solidified at room temperature to obtain a molded thumb adduction orthosis; S3. Assembly of parts: For the molded thumb adduction orthosis, assemble the Velcro. The Velcro should be made of elastic material to increase the traction on the radial side of the thumb.

2. The method for manufacturing a thumb adduction orthosis according to claim 1, characterized in that: In S1, the three-dimensional data of the orthosis obtained by scanning with a 3D scanner is analyzed using DasViewer software. The DasViewer software uses CDEM as the computing core and GPU parallel acceleration to quickly simulate the three-dimensional data of the orthosis.

3. The method for manufacturing a thumb adduction orthosis according to claim 1, characterized in that: In S3, the Velcro is made of nylon.

4. The method for manufacturing a thumb adduction orthosis according to claim 1, characterized in that: In S2, the injection molding of the orthosis shell part includes the following steps: S4. Raw material preparation: The components of thermoplastic polyurethane material include polycaprolactone, plasticizer, anti-adhesive agent, inorganic filler and masterbatch. The specific proportions are: 60-100 parts of polycaprolactone, 0.5 parts of plasticizer, 0.55 parts of anti-adhesive agent, 0.4-0.45 parts of inorganic filler, and 0.4 parts of masterbatch; S5, mixing and melting: After various raw materials are mixed in proportion, they are melted and plasticized through an extruder to form a uniform melt. In this process, the temperature is 65°C-120°C, the pressure is 34MPa-37MPa, and the time is 1-3 minutes to ensure the stability and consistency of the thermoplastic polyurethane material melt; S6. Shell molding: Use a flat heater to heat the material to 60-70°C to soften it and then shape it. The shaped material is operated for 3-5 minutes at room temperature. Adjust the angle and shape it evenly until it cools and sets.

5. The method for manufacturing a thumb adduction orthosis according to claim 1, characterized in that: In S5, the extruder is a flat plate extruder, which crushes the thermoplastic polyurethane material through the rotation of a single screw and converts the thermoplastic polyurethane material into a plastic sheet.

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