Outer-layer fabric for orthopedic external fixation splint and weaving method of outer-layer fabric

Abstract

The invention relates to the technical field of medical braided fabrics, in particular to an outer-layer fabric for an orthopedic external fixation splint, which comprises polyamide fibers, polyester fibers and hollow polyester fibers, and the polyamide fibers, the polyester fibers and the hollow polyester fibers are doped to form knitting yarns; and weaving yarns are interlaced and woven into a sleeve-shaped woven fabric with the thickness of 4-6mm and a honeycomb grid structure through the yarn nozzles A and B. When in use, the warp yarns and the weft yarns are interlaced and woven into the sleeve-shaped woven fabric with the thickness of 4-6mm and the honeycomb-shaped grid structure, so that the fabric is uniform in force distribution in the stretching direction and has good supporting performance and structural stability, and holes in the honeycomb-shaped grid structure have good air permeability and lightness.

Description

Technical Field

[0001] This invention relates to the field of medical woven fabric technology, specifically to an outer layer fabric for orthopedic external fixation splints and its weaving method. Background Technology

[0002] Fractures, bone injuries, and joint injuries are common symptoms in orthopedics. After treatment, patients need to have the fracture site or movable joint immobilized to prevent secondary damage to the affected area from activity or external forces, and to improve the recovery speed of the affected area.

[0003] Existing orthopedic fixation methods involve using plaster casts, fiberglass splints, etc. However, these existing orthopedic fixation devices suffer from being heavy and having poor breathability, leading to discomfort during prolonged wear. Using ordinary polyester or nylon fabric impregnated in polyurethane and cured as a fixation material results in dense pinholes due to the woven structure, leading to poor breathability. Furthermore, the dense woven structure results in significant weight after the polyurethane has cured. Summary of the Invention

[0004] In view of the shortcomings of the prior art mentioned above, the purpose of the present invention is to provide an outer fabric for an orthopedic external fixation splint and a weaving method thereof, in order to solve the problems of poor air permeability and heavy weight after curing of existing ordinary woven fabrics mentioned in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method for weaving a fabric, comprising at least the following weaving steps: S1. Establishing the basic grid structure: The knitting yarn forms continuous loops on the back needle bed and the front needle bed respectively, and alternately forms the basic grid; S2. Forming the central hole of the pineapple flower: The front and back needle beds skip stitches to form staggered holes, and repeatedly alternate to form the "central concave hole" of the pineapple flower; S3. Create the "interlaced raised texture" of the outer ring of the pineapple flower: alternate between the front and back needle beds to "shift the circle - reverse the circle - cover the circle" to form a three-dimensional raised block around the pineapple flower; S4. Repeat the pattern unit to form a continuous pineapple mesh: After completing steps S2 and S3, start knitting the next pineapple pattern unit by skipping stitches, and arrange all the patterns in an orderly manner, forming support holes in the patterns; S5. Reinforcement of dense stitches in the edge finishing area: Knit to the end, cancel skipped stitches and shift stitches, and restore dense stitches.

[0006] Preferably, step S1 includes the following operations: the yarn feeder A of the knitting machine moves to the right to form a continuous loop at a designated needle position on the rear needle bed; the yarn feeder B of the knitting machine moves to the left to knit the corresponding loop on the front needle bed; the yarn feeders A and B alternate moving left and right to form the "grid" basic grid required for the bottom layer of the pineapple pattern on the front and rear needle beds.

[0007] Preferably, step S2 includes the following operations: when the yarn feeder A moves to the right, a skip 2 stitches are performed on the front needle bed to form a loop, creating the central hole of the first set of hexagonal honeycomb mesh structure with a side length of 1.2–2.5 mm; when the yarn feeder B moves to the left, a skip 2 stitches are performed on the rear needle bed to misalign the holes of the front and rear needle beds; the above knitting process is repeated alternately to make the "central concave hole" of the pineapple flower gradually protrude.

[0008] Preferably, the holes of the front and rear needle beds are staggered by 0.5mm and overlapped, and the thickness of the single-layer honeycomb mesh structure is 1.8mm.

[0009] Preferably, step S3 includes the following operations: when knitting to the left of the yarn feeder A, reverse shifting is performed on 4 to 6 stitches to the left and right of the center hole; after knitting to the right of the yarn feeder B, the shifted loops are wrapped into loops to make the loops overlap and form a three-dimensional protrusion around the pineapple flower.

[0010] Preferably, the skip stitch interval in step S4 is 4–6 stitches; the pineapple flower units are arranged continuously in a circular or straight direction.

[0011] Preferably, step S5 includes the following operations: reducing the edge by 1 stitch per row of dense stitches, shifting the loops between the front and back needle beds to make the edge more secure and prevent it from coming off the loop, forming a knitted fabric with a thickness of 4-6mm and a honeycomb mesh.

[0012] A fabric material, which is woven using the aforementioned fabric weaving method.

[0013] Preferably, the yarn used in the fabric includes polyamide fiber, polyester fiber, and hollow polyester fiber, wherein the polyamide fiber, polyester fiber, and hollow polyester fiber are in the following weight ratio: 30-40 parts by weight of polyamide fiber, 40-50 parts by weight of polyester fiber, and 15-25 parts by weight of hollow polyester fiber.

[0014] An outer layer fabric for an orthopedic external fixation splint, comprising a sheath-like woven fabric made from the aforementioned fabric material.

[0015] Compared with the prior art, the beneficial effects of the present invention are: The outer fabric of the orthopedic external fixation splint of the present invention is woven into a sheath-shaped fabric with a thickness of 4-6 mm by interlacing yarn feeders A / B, and has a honeycomb mesh structure. This makes the fabric uniformly distributed in the tensile direction, thus providing good support and structural stability. In addition, the holes in the honeycomb mesh structure have good breathability and lightness.

[0016] The outer fabric of the orthopedic external fixation splint of the present invention is composed of woven yarn made of polyamide fiber, polyester fiber and hollow polyester fiber. The woven yarn has high compatibility with polyurethane adhesive, allowing the polyurethane adhesive to be fully impregnated, thereby improving the support strength and durability after curing. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the weave shape of the woven fabric of the present invention.

[0018] Figure 2 This is a schematic diagram of step one of the weaving method of the present invention.

[0019] Figure 3 This is a schematic diagram of step two of the weaving method of the present invention.

[0020] Figure 4 This is a schematic diagram of step three of the weaving method of the present invention.

[0021] Figure 5 This is a schematic diagram of step five of the weaving method of the present invention. Detailed Implementation

[0022] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described with reference to the accompanying drawings.

[0023] Please see Figures 1-5 It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed in this invention. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0024] like Figure 1 As shown, the present invention provides an outer fabric for an orthopedic external fixation splint, comprising polyamide fibers, polyester fibers and hollow polyester fibers, wherein the polyamide fibers, polyester fibers and hollow polyester fibers are mixed to form a woven yarn; The woven yarn consists of warp and weft threads, which are interwoven to form a woven fabric with a thickness of 4-6mm and a honeycomb mesh structure. This fabric is then combined with polyurethane material and heat-set to form a fabric with good support, wear resistance, lightweight, and breathability. The heat-setting temperature is 120–140℃ to ensure the stability of the honeycomb mesh structure. The fabric has an abrasion resistance of ≥10,000 cycles, and the composite polyurethane backing can withstand an external force of ≥15kg without deformation.

[0025] The addition of polyamide fibers endows the braided yarn with excellent abrasion resistance and impact resistance, effectively resisting friction and collisions that may occur during daily activities and extending the service life of the outer fabric. Polyester fibers, with their high strength and good dimensional stability, provide solid structural support for the fabric, ensuring that the splint is not easily deformed during fixation and maintaining a stable fixation effect on the affected area. The unique hollow structure of hollow polyester fibers significantly reduces the overall weight of the fabric, enhancing the lightness of wearing it. The braided yarn made from the above materials is woven into a honeycomb mesh structure. The pores in the honeycomb mesh structure enhance the breathability of the fabric, effectively reducing the stuffiness when wearing it.

[0026] The honeycomb mesh structure features hexagonal mesh openings with side lengths of 1.2–2.5 mm. This dimension ensures both the overall structural support and excellent breathability. The honeycomb mesh consists of two layers, staggered by 0.5 mm, with each layer being 1.8 mm thick. This double-layered, staggered design enhances the fabric's structural strength and compressive strength through mutual support, allowing for better stress dispersion and preventing localized damage when subjected to external forces. Furthermore, the staggered weave creates a three-dimensional spatial structure that optimizes airflow while maintaining overall fabric support. Air can circulate through the gaps and openings between the layers, significantly improving the poor breathability of traditional padded outer fabrics and effectively reducing the risk of skin stuffiness, sweating, and even inflammation during prolonged wear.

[0027] The polyamide fiber, polyester fiber, and hollow polyester fiber are described in the following weight ratio: 30-40 parts by weight of polyamide fiber, preferably 40 parts by weight of polyamide fiber, with a molecular weight of Mn of 20,000-50,000 and a diameter of 12-20 μm; 40-50 parts by weight of polyester fiber, preferably 45 parts by weight of polyester fiber, with a molecular weight of Mn of 15,000–30,000 and a diameter of 15–25 μm; Hollow polyester fiber 15-25 parts by weight, optimally 15 parts by weight, hollow rate 30-50%, diameter 20-30μm.

[0028] Table 1 Optimal material ratio and characterization parameters

[0029] Table 2 Comparison of the performance of materials with different proportions

[0030] The above data were measured based on the following sources: tensile strength was tested according to GB / T 3923.1-2013 standard; abrasion resistance was tested according to GB / T 21196.2-2007 standard; air permeability was tested according to GB / T 5453-1997 standard; and lightweight was tested based on fabric area density.

[0031] Comparative analysis of different formulations reveals that when the proportions of polyamide fiber (30%), polyester fiber (45%), and hollow polyester fiber (25%) are used (Comparison A), although the highest proportion of hollow fiber results in an air permeability of 280 L / m²·s, the tensile strength is only 1600 N / m, and the abrasion resistance is 7000 cycles. The overall support and durability are insufficient to meet the long-term needs of orthopedic external fixation splints. If the polyester fiber proportion is increased to 50% (Comparison B), with 35% polyamide fiber and 15% hollow polyester fiber, the high proportion of rigid fibers leads to a decrease in fabric softness, an increase in weight of approximately 8%, and a drop in tensile strength to 1500 N / m, further weakening the support compared to Comparison A. Comparison C, using a combination of 35% polyamide fiber, 40% polyester fiber, and 25% hollow polyester fiber, increases the tensile strength to 1650 N / m, achieves 8500 abrasion resistance cycles, and maintains an air permeability of 300 L / m²·s, demonstrating significant weight reduction. However, because the proportion of polyamide fiber is not optimal, there is still room for improvement in overall strength. The preferred blend of 40% polyamide fiber, 45% polyester fiber, and 15% hollow polyester fiber in this invention optimizes the ratio of high-strength abrasion-resistant components to functional fibers, achieving a tensile strength of 1800 N / m, abrasion resistance of 10,000 cycles, and an air permeability of 320 L / m²·s. While ensuring the fabric's lightweight (area density ≤0.35 kg / m²), it also takes into account support stability and wearing comfort, and its overall performance is significantly better than other blending schemes.

[0032] like Figures 2-5 As shown, a method for weaving the outer fabric of an orthopedic external fixation splint includes the following weaving steps: S1. Establishing the basic lattice structure: The yarn feeder A of the knitting machine moves to the right and forms a continuous loop at the designated needle position on the rear needle bed; The yarn feeder B of the knitting machine moves to the left and knits the corresponding loop on the front needle bed; The yarn feeders A and B alternate left and right, so that the front and back needle beds form the basic grid of the "ticknit" pattern needed for the bottom layer of the pineapple pattern; The basic mesh has a transverse density of 8-10 stitches per centimeter and a longitudinal density of 7-9 stitches per centimeter. Precise control of the stitch length and loop tension ensures the stability of the subsequent pineapple pattern. The yarn used in yarn feeders A and B has a linear density of 280-320 dtex and employs a twisting process (80-100 twists / meter) to enhance the tensile strength and structural stiffness of the basic mesh.

[0033] S2. Forming the central hole of the pineapple flower: When the yarn feeder A moves to the right, it performs a skip 2 stitches to form a loop on the front needle bed (skip stitch → empty stitch → loop), forming the first set of central holes. The large central hole in the pineapple flower pattern can improve air permeability and resin impregnation speed. When the yarn feeder B moves to the left, it performs a skip 2 stitches to form a loop on the back needle bed, causing the holes of the front and back needle beds to be misaligned; Move one stitch towards the center on each side of the skipped stitch area to create a closing effect around the hole; Repeat the above weaving process alternately to gradually make the "central concave hole" of the pineapple flower more prominent; This staggered design not only avoids the structural strength loss caused by direct connection between the front and back needle bed holes, but also forms a "maze-like" ventilation channel through the staggered distribution of the holes, ensuring air circulation while enhancing the fabric's ability to block external particles. The gathering effect is achieved by moving the first stitch loop on the left side of the skipped stitch area to the right of the looping needle position, and the first stitch loop on the right side to the left of the skipped stitch position, causing the originally loose loops to gather towards the center. The edge of the hole changes from a straight line to an inward curve, creating a visually distinct concave effect. In actual knitting, after every three alternating cycles of yarn feeders A and B, a tension compensation adjustment (the tension value is set to 1.2 times the base knitting tension) is required to prevent the holes from deforming due to loop loosening during long-term knitting.

[0034] S3. Establish the "interlaced raised texture" on the outer ring of the pineapple pattern, forming the characteristic "raised grid on the outer ring" of the pineapple pattern, thereby improving structural strength and outer protective performance: When knitting to the left of needle A, perform a reverse shift on the 4-6 stitches to the left and right of the center hole (shift from left to right and from right to left). After knitting to the right with needle B, wrap the loops after the above transfer into loops (crossing over one stitch before looping) to overlap the loops; The front and rear needle beds alternately perform "shifting circles - reverse shifting circles - wrapping circles" to form a three-dimensional raised block around the pineapple flower pattern; These staggered protrusions, with a height of 0.8–1.2 mm, create a 1.5–2.0 mm height difference with the central concave hole. This not only enhances the friction of the fabric surface, effectively preventing slippage during wear, but also further optimizes the ventilation path through the gaps between the protrusions. In practice, the number of stitches for reverse loop transfer is set according to the pineapple pattern size. Typically, for every 0.5 mm increase in the diameter of the central hole, the number of stitches involved in the reverse loop transfer on the outer ring increases by one, ensuring a harmonious size ratio between the raised pattern and the concave hole, maintaining the overall structural balance. During wrap-around loop formation, the yarn must be wrapped around the root of the loop from the previous needle bed before knitting, allowing the new loop to tightly wrap the old loop, forming a "knot-like" reinforcing structure. Tests have shown that this structure can increase the local tensile strength of the raised pattern area by approximately 15%.

[0035] S4. Repeating floral units form a continuous pineapple mesh pattern: After completing steps S2 and S3, skip 4-6 stitches and begin knitting the next pineapple flower unit. Arrange all flower patterns continuously along a circular or straight line; S5. The edge finishing area is reinforced with dense mesh to prevent loosening and curling: At both ends of the fabric, eliminate skipped stitches and loop shifts, and restore dense stitches; tighten the edges by decreasing one stitch per row; shift the loops between the front and back needle beds to make the edges more secure and prevent them from coming off the loops; The above steps are repeated continuously until a knitted structure resembling a sleeve or sock is formed.

[0036] Table 3. Instructions for Weaving Methods

[0037] In summary, the outer fabric of the orthopedic external fixation splint of the present invention is a sheath-shaped woven fabric with a thickness of 4-6 mm and a honeycomb mesh structure, formed by interlacing warp and weft threads. This makes the fabric uniformly distributed in the tensile direction, providing good support and structural stability. Furthermore, the pores in the honeycomb mesh structure have good breathability and lightness.

[0038] The outer fabric of the orthopedic external fixation splint of the present invention is composed of woven yarn made of polyamide fiber, polyester fiber and hollow polyester fiber. The woven yarn has high compatibility with polyurethane adhesive, allowing the polyurethane adhesive to be fully impregnated, thereby improving the support strength and durability after curing.

[0039] The above description is merely an illustrative embodiment of the present invention and is not intended to limit the scope of the invention. Any equivalent changes and modifications made by those skilled in the art without departing from the concept and principles of the present invention should fall within the scope of protection of the present invention. Furthermore, it should be noted that the components of the present invention are not limited to the overall application described above. Each technical feature described in the specification can be used individually or in combination as needed. Therefore, the present invention naturally covers other combinations and specific applications related to the inventive points of this case.

Claims

1. A method for weaving a fabric, characterized in that, At a minimum, the following knitting steps are required: S1. Establishing the basic grid structure: The knitting yarn forms continuous loops on the back needle bed and the front needle bed respectively, and alternately forms the basic grid; S2. Forming the central hole of the pineapple flower: The front and back needle beds skip stitches to form staggered holes, and repeatedly alternate to form the "central concave hole" of the pineapple flower; S3. Create the "interlaced raised texture" of the outer ring of the pineapple flower: alternate between the front and back needle beds to "shift the circle - reverse the circle - cover the circle" to form a three-dimensional raised block around the pineapple flower; S4. Repeat the pattern unit to form a continuous pineapple mesh: After completing steps S2 and S3, start knitting the next pineapple pattern unit by skipping stitches, and arrange all the patterns in an orderly manner, forming support holes in the patterns; S5. Reinforcement of dense stitches in the edge finishing area: Knit to the end, cancel skipped stitches and shift stitches, and restore dense stitches.

2. The method for weaving a fabric according to claim 1, characterized in that: Step S1 includes the following operations: the yarn feeder A of the knitting machine moves to the right to form a continuous loop at the designated needle position on the rear needle bed; the yarn feeder B of the knitting machine moves to the left to knit the corresponding loop on the front needle bed; the yarn feeders A and B alternate moving left and right to form the "grid" basic grid required for the bottom layer of the pineapple pattern on the front and rear needle beds.

3. The method for weaving a fabric according to claim 2, characterized in that: Step S2 includes the following operations: When the yarn feeder A moves to the right, a skip 2 stitches are performed on the front needle bed to form a loop, creating the central hole of the first set of hexagonal honeycomb mesh structure with a side length of 1.2–2.5 mm; when the yarn feeder B moves to the left, a skip 2 stitches are performed on the back needle bed to make the holes of the front and back needle beds misaligned; the above knitting process is repeated alternately to make the "central concave hole" of the pineapple flower gradually protrude.

4. The method for weaving a fabric according to claim 3, characterized in that: The holes of the front and rear needle beds are staggered by 0.5mm and overlapped, and the thickness of the single-layer honeycomb mesh structure is 1.8mm.

5. The method for weaving a fabric according to claim 4, characterized in that: Step S3 includes the following operations: when knitting on the left side of the yarn feeder A, reverse transfer is performed on 4 to 6 stitches to the left and right of the center hole; after knitting on the right side of the yarn feeder B, the loops after the transfer are wrapped into loops, so that the loops overlap and a three-dimensional convex block is formed on the outside of the pineapple flower.

6. The method for weaving a fabric according to claim 5, characterized in that: The skip stitch interval in step S4 is 4–6 stitches; the pineapple flower units are arranged continuously in a circular or straight direction.

7. The method for weaving a fabric according to claim 6, characterized in that: Step S5 includes the following operations: reduce the edge by 1 stitch per row of dense stitches, and shift the loops between the front and back needle beds to make the edge more secure and prevent it from coming off the loop, forming a knitted fabric with a thickness of 4-6mm and a honeycomb mesh.

8. A fabric material, characterized in that: It is woven by the weaving method of any one of claims 1-7.

9. The fabric according to claim 8, characterized in that: The fabric uses yarns comprising polyamide fibers, polyester fibers, and hollow polyester fibers, wherein the polyamide fibers, polyester fibers, and hollow polyester fibers are in the following weight ratio: 30-40 parts by weight of polyamide fiber, 40-50 parts by weight of polyester fiber, and 15-25 parts by weight of hollow polyester fiber.

10. An outer fabric for an orthopedic external fixation splint, characterized in that: A sheath-shaped woven fabric made from the fabric described in any one of claims 8-9.

Images