Inner-layer fabric for external fixation splint for orthopedics department and weaving method of inner-layer fabric

Abstract

The invention relates to the technical field of medical braided fabrics, in particular to an inner-layer fabric for an orthopedic external fixation splint, which comprises polyamide fibers, polyester fibers, hollow polyester fibers and nanowires, and the polyamide fibers, the polyester fibers, the hollow polyester fibers and the nanowires are doped to form braided yarns; the weaving yarns are divided into warp yarns and weft yarns, the yarn carrier A and the yarn carrier B are woven in a staggered manner to form a sleeve-shaped fabric which is 2mm in thickness and is provided with twill groove-shaped structures, and air holes are formed among the twill groove-shaped structures. When in use, the warp yarns and the weft yarns are woven in a staggered manner to form the sleeve-shaped fabric which is 2mm in thickness and is provided with the twill groove-shaped structures, and the air holes are formed among the twill groove-shaped structures, so that after wearing, groove-shaped three-dimensional structure units can be formed through the twill groove-shaped structures, and the groove-shaped three-dimensional structure units are used for improving air permeability, reducing water vapor accumulation and improving moisture-conducting and sweat-discharging capabilities.

Description

Technical Field

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

[0002] In orthopedic surgery, splints are often used to fix fractures or bone injuries in order to prevent secondary damage and speed up recovery.

[0003] Current orthopedic external fixation splints often use an inner fabric layer worn directly against the skin to isolate the outer splint and improve patient comfort. However, the inner fabric of these splints is typically woven using ordinary weaving methods, and the weave is very fine to prevent external hardening agents from penetrating the skin. This results in several drawbacks: poor breathability, leading to moisture buildup and stuffiness; limited moisture wicking, causing sweat retention and skin maceration or inflammation; insufficient structural elasticity, causing wrinkling or curling during wear and limb bending; and difficulty in balancing softness and support, ultimately affecting comfort. Summary of the Invention

[0004] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide an inner layer fabric for orthopedic external fixation splints and a weaving method thereof, in order to solve the problem of discomfort in use 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. Establishment of the bottom dense needle zone: The left and right needles of the knitting machine's yarn feeder form a basic dense needle layer distributed front and back on the needle bed; S2. Forming corn kernel bumps: During the left and right needle movement of the yarn feeder of the braiding machine, the front needle bed regularly raises the loop length, and the rear needle bed is correspondingly misaligned and wraps around to form bumps, forming corn kernel bumps, and repeats the braiding process so that the corn kernels appear periodically. S3. The staggered arrangement of the convex dots forms a "corn kernel array": In the next cycle of the fabric, the convex dot weaving position is shifted, and this is repeated to make the convex dots arranged in an alternating pattern. S4. Micro-skip stitch treatment in local air-permeable areas: Perform a skip stitch in the concave area between corn kernels to form micro-air-permeable holes; S5. Reinforcement of the edge of the knitted fabric: Eliminate the loops at the edge of the fabric, only do dense knitting, and decrease stitches to tighten.

[0006] Preferably, step S1 includes the following operations: the yarn feeder A of the knitting machine moves to the right to form a basic dense needle layer on the front needle bed; the yarn feeder B of the knitting machine moves to the left to form a corresponding dense needle layer on the rear needle bed.

[0007] Preferably, in step S1, the yarn feeder B simultaneously forms loops with the front and rear needle beds, creating the first layer of the corn kernel texture.

[0008] Preferably, step S2 includes the following operation: when the yarn feeder A moves to the left, the front needle bed performs a loop lifting action according to the interval pattern of the 3rd, 6th, 9th... needles to increase the loop length; When the yarn feeder B moves to the right, it moves the corresponding needle position on the back needle bed forward by 1 stitch, causing misalignment. The yarn feeder A moves to the right again to form a loop, so that the loop after lifting is covered, forming a raised point with a height of 0.2–0.4 mm; Repeat the above steps every two rows to make the corn kernels appear periodically at intervals of 0.8–1.2 mm, forming micro-convex units and pineapple-like structures.

[0009] Preferably, step S3 includes the following operations: shifting the entire convex knitting position 2 stitches to the right, and then shifting the entire position 2 stitches to the left in the next cycle to form a knitted body with a thickness of 2mm, and repeating this process to make the convex points arranged in an interlaced pattern and have diagonal moisture-wicking grooves with a horizontal width of 300μm and a vertical width of 200–400μm.

[0010] Preferably, step S4 includes the following operation: the coils on both sides of the micro-hole are fixed by small-amplitude coil shifting.

[0011] Preferably, step S5 includes the following operations: decreasing 1 stitch every 2 rows to slightly tighten the edge, and shifting the front and back needle beds to each other.

[0012] A woven fabric, which is woven cyclically using any of the above-described weaving methods.

[0013] Preferably, the yarn used in the fabric comprises polyamide fiber, polyester fiber, hollow polyester fiber, and nanofiber, wherein the polyamide fiber, polyester fiber, hollow polyester fiber, and nanofiber are in the following weight ratio: 30-50 parts by weight of polyamide fiber, 30-40 parts by weight of polyester fiber, 15-25 parts by weight of hollow polyester fiber, and 5-10 parts by weight of nanofiber.

[0014] An inner layer fabric for an orthopedic external fixation splint, comprising a sheath-like fabric made from the woven fabric described in any one of the preceding claims.

[0015] Compared with the prior art, the beneficial effects of the present invention are: The inner layer fabric of the orthopedic external fixation splint of the present invention is formed by interlacing yarn nozzles A and B to form a sleeve-shaped fabric with a thickness of 2mm and a twill groove structure. Breathable holes are set between the twill groove structure, so that after wearing, the twill groove knots can form a groove-shaped three-dimensional structural unit to improve breathability, reduce moisture accumulation, and increase moisture wicking capacity.

[0016] The inner fabric of the orthopedic external fixation splint of the present invention enhances in-plane support and prevents curling by setting corn kernel-shaped protrusions, and can quickly wick away moisture and sweat through the radish-shaped groove structure to keep the skin dry, thereby achieving both softness and support while improving wearing comfort. 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 four of the weaving method of the present invention.

[0022] Figure 6 This is a schematic diagram of step five of the weaving method of the present invention. Detailed Implementation

[0023] 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.

[0024] Please see Figures 1-6 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.

[0025] like Figure 1As shown, this invention provides an inner fabric for an orthopedic external fixation splint, comprising polyamide fibers, polyester fibers, hollow polyester fibers, and nanofibers. The polyamide fibers, polyester fibers, hollow polyester fibers, and nanofibers are doped together to form a woven yarn, which is then woven to form the fabric. The nanofiber layer is treated with chitosan or silver ions to achieve an antibacterial rate of ≥90%. The woven yarn consists of warp and weft yarns, which are interwoven to form a 2mm thick, twill-grooved fabric for wearing over joints such as the wrist, arm, thigh, and calf. Ventilation holes are provided between the twill-grooved structures. The fabric undergoes heat setting at 110–130℃ to maintain the hollow polyester fiber bulkiness at ≥90% and the overall air permeability at ≥350 L / m²·s. When the inner fabric comes into contact with the skin, the micro-convex units in the twill-grooved structure support the fabric body, creating tiny air gaps of 0.2–0.4mm on the skin surface. This effectively reduces the direct contact area between the fabric and the skin, preventing stuffiness caused by tight fit. Simultaneously, these air gaps act as channels for heat exchange, promoting heat dissipation from the skin surface. The small but densely distributed ventilation holes between the twill-grooved structures allow moisture from skin respiration and ambient air to circulate freely, preventing moisture buildup between the fabric and the skin. In particular, the moisture-wicking channels formed by the longitudinal groove units, with a width of 200–400 μm, and the equidistant offset design, allow water vapor to be quickly discharged along the grooves. Even when patients sweat due to activity or increased ambient temperature, the moisture generated by the evaporation of sweat can be quickly discharged to the outside of the fabric, thereby significantly improving the problem of skin stuffiness caused by the poor breathability of traditional inner layer fabrics and keeping the skin surface dry and comfortable.

[0026] The polyamide fiber, polyester fiber, hollow polyester fiber, and nanofiber are in the following weight ratio: 30-50 parts by weight of polyamide fiber, molecular weight Mn 20,000–50,000, diameter 12–20 μm; Polyester fiber, 30-40 parts by weight, molecular weight Mn 15,000–30,000, diameter 15–25 μm; Hollow polyester fiber, 15-25 parts by weight, hollowness 30-50%, diameter 20-30μm; Nanofibers, 5-10 parts by weight, with a fiber diameter of 0.05–1 μm and a thickness of 1–30 μm.

[0027] Table 1 Optimal material ratio and characterization parameters

[0028] Table 2 Comparison of Woven Fabric Performance under Different Material Weight Ratios

[0029] The test data above are sourced from the following sources: breathability was tested according to GB / T 5453-1997 standard, moisture absorption rate was tested according to a custom capillary test standard, antibacterial rate was tested according to ASTM E2149 standard, and comfort was tested based on clinical simulation wearing.

[0030] As can be seen from the data in the table above, when the weight ratio of polyamide fiber (PA), polyester fiber (PET), hollow polyester fiber (HollowPET), and nanofiber is 40 / 30 / 20 / 10, the air permeability of the prepared inner layer fabric reaches 350 L / m²·s, significantly higher than that of comparison A (240 L / m²·s), comparison B (310 L / m²·s), and comparison C (300 L / m²·s). This is due to the 15-25% proportion of hollow polyester fiber, whose 30-50% hollowness and 20-30 μm diameter provide abundant air circulation channels inside the fabric. Combined with the twill groove structure and micro-pores formed by the specific weaving method, these factors jointly improve the overall air permeability. In terms of antibacterial rate, the preferred formulation of this invention achieves 93.2%, far surpassing Comparison A's 75.6%, Comparison B's 70.8%, and Comparison C's 81.4%. This is mainly attributed to the addition of 10% nanofibers, which, after treatment with chitosan or silver ions, effectively inhibit bacterial growth. Regarding comfort rating (out of 10), the preferred formulation of this invention achieves a high score of 9.5. Comparison A, due to its excessively high PA content (50%), results in stiff fabric and a comfort score of only 7.5. Comparison B, with its 40% PET content, while offering improved softness, suffers from insufficient support and is prone to curling, resulting in a comfort score of 8.0. Comparison C exhibits mediocre overall performance, with inferior antibacterial effect and overall balance compared to this invention, achieving a comfort score of 8.3. This invention, through precise control of the weight ratio of each fiber component, successfully achieves the optimal balance between breathability, antibacterial properties, and comfort in the fabric, fully meeting the clinical needs of orthopedic external fixation splint inner layer fabric for "soft and skin-friendly, breathable and sweat-wicking, and long-lasting antibacterial properties."

[0031] In some embodiments, the twill groove structure of the present invention includes corn kernel-shaped micro-convex units formed by alternating warp yarn floats, with each warp yarn float forming a 0.3 mm convex point every 3 wefts, and pineapple flower-shaped structures formed by alternating superposition of longitudinal groove units through periodic offset of 3 floats between warp and weft yarns; the convex point spacing of the micro-convex units is 0.8–1.2 mm, the height is 0.2–0.4 mm, and the groove width of the groove units is about 300 μm; through the combination of micro-convex units and groove units, the woven fabric can achieve an elastic recovery rate of 92%, an in-plane stiffness increase of 15%, a moisture wicking rate increase of about 35%, and no stuffy or uncomfortable reaction in skin simulation tests.

[0032] like Figures 2-6As shown, a method for weaving the inner layer fabric of an orthopedic external fixation splint includes the following weaving steps: S1. Establishment of the bottom layer dense needle area: The yarn feeder A of the knitting machine moves to the right and forms a basic dense stitch on the front needle bed; The yarn feeder B of the knitting machine moves to the left and forms corresponding dense needles on the rear needle bed. At the same time, the front and rear needle beds alternate to form circles, forming the first layer of the corn kernel texture. When the yarn feeder B of the knitting machine moves to the left, loop knitting is performed on the back needle bed corresponding to the dense needle position of the front needle bed. By alternately hooking the yarn on the front and back needle beds, the loops are interlocked to form a tightly fitted bottom layer structure. This layer contains about 80-100 loops per square centimeter, providing stable support for the subsequent formation of bumps. At the same time, yarn feeders A and B maintain a stable yarn tension of 25-35cN during the knitting process to ensure uniform loop size and avoid texture deformation caused by tension fluctuations.

[0033] S2, Forming corn kernel bumps: When the yarn feeder A moves to the left, the front needle bed performs a loop-lifting action according to the interval pattern of the 3rd, 6th, 9th... stitches, increasing the loop length; When the yarn feeder B moves to the right, it moves the corresponding needle position on the back needle bed forward by 1 stitch, causing misalignment. The yarn feeder A moves to the right again to form a loop, so that the loop after lifting is covered, forming a raised point; Repeat the above steps every two rows to make the corn kernels appear periodically; During the leftward movement of yarn feeder A, the needle selection mechanism of the front needle bed, according to a preset program, drives the knitting needles to rise to a certain height to perform a loop-lifting action based on the pattern of the 3rd, 6th, 9th... stitches (i.e., every 2 stitches). This action stretches the length of the corresponding loop to 1.5-2 times that of a normal loop. Yarn feeder B then moves to the right. When knitting to the rear needle bed, the control system instructs the knitting needle at the corresponding needle position to move forward by 1 stitch, forming a lateral misalignment with the loop-lifting needle position of the front needle bed. Next, yarn feeder A moves to the right again, forming a loop on the adjacent needle of the loop-lifting needle position of the front needle bed. The newly formed loop covers the previously stretched loop portion, causing the area to form a three-dimensional raised point with a height of about 0.3mm due to the accumulation of loops. To ensure that the raised points are evenly and regularly distributed, the above combination of loop lifting, misalignment, and covering actions is repeated every 2 rows during the knitting process, ultimately making the corn kernel-like raised points periodically arranged along the transverse direction of the fabric, with a transverse spacing of about 1.0mm between adjacent raised points.

[0034] S3. The staggered arrangement of the protrusions forms a "corn kernel array": In the next cycle of the fabric, move the entire position of the raised dots 2 stitches to the right, and then move the entire position 2 stitches to the left in the next cycle, repeating this process to make the raised dots arranged in an alternating pattern; In the next cycle of knitting, the control system adjusts the needle selection program, shifting the knitting position where the bumps were originally formed at needle positions 3, 6, 9... to the right by 2 needle positions. That is, the lifting, staggering, and covering actions are performed at needle positions 5, 8, 11... When entering the next cycle, the knitting position of the bumps is shifted to the left by 2 needle positions, returning to a needle position pattern similar to the initial cycle (such as near needle positions 3, 6, 9..., but minor adjustments may occur due to the cumulative shift). Through this cycle pattern of shifting 2 needles to the left and right, the bumps of the corn kernels in adjacent rows are arranged in an alternating pattern in the horizontal position, rather than being completely aligned. This staggered arrangement allows the protrusions to form a more uniform support matrix in the plane. The longitudinal spacing between adjacent protrusions is maintained at 1.2-1.5mm, and the lateral misalignment distance is about 0.5-0.6mm. This effectively avoids local pressure concentration that may be caused by the protrusions being completely aligned, and further enhances the overall elastic recovery ability of the fabric. Tests have shown that after adopting this staggered arrangement, the uniformity of the in-plane support force distribution of the fabric is improved by about 20%. In the tensile test simulating limb activity, the deformation consistency of the protrusion array is better, and it is less likely to cause local collapse or overstretching.

[0035] S4. Micro-skipped stitch treatment in localized breathable areas: Perform a skip stitch in the recessed area between the corn kernels to create micro-ventilation holes; The coils on both sides of the micro-hole are fixed by slight coil shifting; The skip stitch position is selected in the transverse concave area between adjacent corn kernel protrusions, specifically at the center of every four corn kernel protrusions forming a diamond-shaped unit. The knitting machine's needle selection system pauses loop formation at the corresponding needle position, creating a micro-ventilation hole with a diameter of approximately 150–200 μm, with about 15–20 ventilation holes distributed per square centimeter. At adjacent needle positions on both sides of the micro-ventilation hole, yarn feeder A and yarn feeder B shift 0.5 stitch lengths towards the ventilation hole during loop formation. The loops at the edge of the ventilation hole are tightened and fixed by the transverse tension of the loops, preventing the ventilation hole from deforming and expanding due to stress during subsequent use, while ensuring the structural stability of the ventilation hole. Tests show that after this treatment, the pore size variation coefficient of the ventilation hole is ≤8%, and it still retains more than 95% of its original shape after 100 stretching cycles.

[0036] S5. Reinforced elasticity at the edges of woven fabrics: Remove the loops at the edge of the fabric and only do close stitch knitting. Decrease 1 stitch every 2 rows to slightly tighten the edge. Move the front and back needle beds back and forth to make the edge flat and prevent curling.

[0037] In the fabric edge area, the knitting program automatically cancels the loop lifting action in step S2. Both yarn feeder A and yarn feeder B are knitted in the same way as the bottom dense needle area in S1, forming a pure dense needle structure without protrusions. At the same time, to prevent the edge from curling due to loose loops, the control system starts the decrease-off program when knitting 5-8 rows away from the edge. That is, one stitch is reduced at the edge position every 2 rows, and the edge contour is naturally formed by gradually tightening the loops. In addition, during the decrease-off process, the needles of the front and back needle beds will periodically move back and forth. The loops of 1-2 stitches at the edge of the front needle bed will be hooked and looped by the corresponding needles of the back needle bed. The loops at the edge of the back needle bed will also be looped back and forth with the front needle bed. This cross-locking process can increase the tear resistance of the edge by 25%, and after 50 repeated bending tests, there is no obvious curling of the edge, maintaining a flat and close fit when in contact with the skin. Repeat the knitting process until a sleeve-like or sock-like knitted structure is formed.

[0038] Table 3. Instructions for Weaving Methods

[0039] In summary, the inner layer fabric of the orthopedic external fixation splint of the present invention is formed by interlacing yarn feeders A and B to form a sleeve-shaped fabric with a thickness of 2mm and a twill groove structure, and ventilation holes are set between the twill groove structure. Thus, after wearing, the twill groove knots can form a groove-shaped three-dimensional structural unit to improve breathability, reduce moisture accumulation, and increase moisture wicking capacity.

[0040] The inner fabric of the orthopedic external fixation splint of the present invention enhances in-plane support and prevents curling by setting corn kernel-shaped protrusions, and can quickly wick away moisture and sweat through the radish-shaped groove structure to keep the skin dry, thereby achieving both softness and support while improving wearing comfort.

[0041] 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, It should include at least the following weaving steps: S1. Establishment of the bottom dense needle zone: The left and right needles of the knitting machine's yarn feeder form a basic dense needle layer distributed front and back on the needle bed; S2. Forming corn kernel bumps: During the left and right needle movement of the yarn feeder of the braiding machine, the front needle bed regularly raises the loop length, and the rear needle bed is correspondingly misaligned and wraps around to form bumps, forming corn kernel bumps, and repeats the braiding process so that the corn kernels appear periodically. S3. The staggered arrangement of the convex dots forms a "corn kernel array": In the next cycle of the fabric, the convex dot weaving position is shifted, and this is repeated to make the convex dots arranged in an alternating pattern. S4. Micro-skip stitch treatment in local air-permeable areas: Perform a skip stitch in the concave area between corn kernels to form micro-air-permeable holes; S5. Reinforcement of the edge of the knitted fabric: Eliminate the loops at the edge of the fabric, only do dense knitting, and decrease stitches to tighten.

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 basic dense stitch layer on the front needle bed; the yarn feeder B of the knitting machine moves to the left to form a corresponding dense stitch layer on the rear needle bed.

3. The method for weaving a fabric according to claim 2, characterized in that: In step S1, the yarn feeder B simultaneously alternates between the front and back needle beds to form circles, creating the first layer of the corn kernel texture.

4. The method for weaving a fabric according to claim 3, characterized in that: Step S2 includes the following operations: When the yarn feeder A moves to the left, the front needle bed performs a loop lifting action according to the interval pattern of the 3rd, 6th, 9th... stitches to increase the loop length; When the yarn feeder B moves to the right, it moves the corresponding needle position on the back needle bed forward by 1 stitch, causing misalignment. The yarn feeder A moves to the right again to form a loop, so that the loop after lifting is covered, forming a raised point with a height of 0.2–0.4 mm; Repeat the above steps every two rows to make the corn kernels appear periodically at intervals of 0.8–1.2 mm, forming micro-convex units and pineapple-like structures.

5. The method for weaving a fabric according to claim 4, characterized in that: Step S3 includes the following operations: shift the entire convex knitting position 2 stitches to the right, and then shift the entire position 2 stitches to the left in the next cycle to form a knitted body with a thickness of 2mm. Repeat this process to make the convex points arranged in an interlaced pattern and have diagonal moisture-wicking grooves with a horizontal width of 300μm and a vertical width of 200–400μm.

6. The method for weaving a fabric according to claim 5, characterized in that: Step S4 includes the following operation: the coils on both sides of the micro-hole are fixed by small-amplitude coil shifting.

7. The method for weaving a fabric according to claim 6, characterized in that: Step S5 includes the following operations: decrease 1 stitch every 2 rows to slightly tighten the edge, and move the front and back needle beds alternately.

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

9. A woven fabric according to claim 8, characterized in that: The fabric uses yarns comprising polyamide fibers, polyester fibers, hollow polyester fibers, and nanofibers, wherein the polyamide fibers, polyester fibers, hollow polyester fibers, and nanofibers are in the following weight ratio: 30-50 parts by weight of polyamide fiber, 30-40 parts by weight of polyester fiber, 15-25 parts by weight of hollow polyester fiber, and 5-10 parts by weight of nanofiber.

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

Images