Apertured Thermoplastic Splint with Composite Mesh
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Solution Overview
Problem
Traditional splint materials like Plaster of Paris are heavy, bulky, have slow setting times, and are not breathable, leading to skin maceration and discomfort, while thermoplastic mesh requires multiple layers and trimming, causing sharp edges and bacterial growth issues.
Innovation Solution
A geometrically apertured protective splint device made from re-mouldable thermoplastic material with optimized strength-to-openness ratios, featuring a composite material with polycaprolactone and lignocellulose additives, providing flexibility, breathability, and ease of application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Plaster of Paris is used for casting, then immobilisation is achieved, but the material is heavy, bulky, and not breathable
Solution Approach 1:
The patent uses a composite material consisting of a thermoplastic polymer matrix combined with a fibrous reinforcement network. This composite structure provides the necessary mechanical strength for immobilisation while the thermoplastic matrix allows for breathability and moisture transmission, overcoming the limitations of traditional Plaster of Paris.
Solution Approach 2:
The thermoplastic mesh structure inherently provides porosity and open spaces that allow air circulation and moisture transmission. This porous configuration enables the cast to be breathable while maintaining structural integrity through the fibrous reinforcement, eliminating the need for heavy non-porous materials like Plaster of Paris.
2Strength
If Plaster of Paris is used for casting, then immobilisation is achieved, but the setting time is slow (24-72 hours)
Solution Approach 1:
The patent employs a thermoplastic material that undergoes a phase change from solid to softened state when heated, and then back to solid upon cooling. This parameter change allows for rapid forming and setting (minutes rather than hours), dramatically reducing the setting time compared to Plaster of Paris while maintaining adequate immobilisation strength through the fibrous reinforcement.
3Object-affected harmful factors
If thermoplastic mesh is used, then breathability is improved, but multiple layers are needed to achieve sufficient strength
Solution Approach 1:
The patent creates a composite structure where a thermoplastic mesh provides breathability and a fibrous reinforcement network provides mechanical strength. This single-layer composite eliminates the need for multiple separate mesh layers, simplifying the device structure while simultaneously achieving both breathability and sufficient strength requirements.
4Adaptability or versatility
If thermoplastic mesh is trimmed to fit body areas, then adaptability is improved, but sharp edges are formed
Solution Approach 1:
The patent uses the thermoplastic material's ability to soften when heated to reshape and smooth the edges of the mesh during application. This parameter change allows the mesh to be heated, molded to fit body contours, and have its edges rounded off simultaneously, achieving adaptability without creating sharp edges that could harm the patient.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device offers superior strength, breathability, and comfort by maintaining alignment and reducing swelling, while being easy to apply and remove, with enhanced mechanical properties and biodegradability, allowing for efficient healing and reduced risk of skin maceration.
Implementation Method 1
the material usually heated using a hot water bath to soften the material to facilitate moulding
Implementation Method 2
At ambient temperature, the material is substantially rigid
Data Source
AI summary
A protective and/or splint device, for example a distal radial splint device (200), comprises a protective and/or splint member (201) and a spacer member (13). The protective and/or splint member (201) comprises a composite protective and/or splint material and is formable at a forming temperature and is substantially rigid at ambient temperature. The material comprises a polycaprolactone and a ligno-cellulose additive material. The protective and/or splint member (201) comprises a mesh of elements (202), with a plurality of openings (203) through the protective and/or splint member (201). Away from the periphery of the splint member (201), the openings (203) are diamond-shaped. Two border elements (204) extend along the two sides of the periphery of the splint member (201). The three point bending strength to openness ratio of the member is greater than 0.1 and the unidirectional bending strength to openness ratio of the member is greater than 4. This results in a device (200) with sufficient strength, which is breathable with open surfaces, and the volume of material used is optimized. The strength of the member (201) parallel to the longitudinal direction of the arm is greater than the strength parallel too the circumferential direction. At the forming temperature the member (201) is stretchable. The member (201) is rounded between the outer surface of the member (201) and the edges around the openings (203).