Selective Encapsulation of Carrier Core in Orthopedic Damping Element
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Solution Overview
Problem
The production of multi-part orthopedic damping or support elements is complex and costly, requiring multiple process steps and various materials, making it difficult to achieve consistent mechanical properties and quality.
Innovation Solution
A one-step method involving a dimensionally stable carrier core selectively encapsulated with a molding compound using a casting tool with a sealing means, such as an elastic sealing lip, to create an integral molded part with targeted mechanical and damping properties, allowing for zones of varying mechanical resistance and damping without the need for additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple process steps and materials are used to produce multi-part orthopedic damping or support elements, then targeted support and damping functions can be achieved, but production complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate components (carrier core, damping layers, cover layers) and multiple production steps into a single integral molded part produced in one injection molding process. The molding compound is injected around a carrier core in a closed casting tool, creating an integrated structure that eliminates the need for separate assembly steps while maintaining targeted mechanical properties through selective encapsulation of the carrier core.
Solution Approach 2:
The patent applies segmentation by creating zones of different mechanical properties within the single molded part. The carrier core is selectively encapsulated in certain areas while left exposed in others, creating distinct functional zones (encapsulated vs. non-encapsulated) that provide different support and damping characteristics without requiring separate components.
2Adaptability or versatility
If multiple process steps are used to apply damping layers and cover layers, then orthopedic function can be optimized, but manufacturing time and cost increase
Solution Approach 1:
The patent merges the production of the carrier core, damping layers, and cover layers into a single injection molding operation. The molding compound is injected in one continuous process to form all functional layers simultaneously, eliminating sequential assembly steps and significantly improving manufacturing efficiency while maintaining the ability to optimize orthopedic function through material selection and geometric design.
3Strength
If different materials are used for carrier core and damping layers, then mechanical properties can be optimized, but quality consistency becomes difficult to achieve
Solution Approach 1:
The patent uses the same molding compound for both the carrier core and the damping/cover layers, ensuring homogeneous material properties throughout the entire part. This single-material approach eliminates variability introduced by joining different materials, ensuring consistent quality and mechanical properties across all production batches while still allowing geometric variation to provide different functional characteristics.
4Strength
If the carrier core is completely surrounded by foam molding compound, then structural integrity is improved, but targeted cushioning function is reduced
Solution Approach 1:
The patent segments the encapsulation of the carrier core by selectively enclosing it with molding compound in certain areas while leaving other areas exposed. This creates distinct functional zones: encapsulated regions provide structural support and targeted cushioning, while non-encapsulated regions allow direct contact between the carrier core and external environment, enabling differentiated mechanical responses in different areas of the orthopedic device.
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
This method simplifies the production of orthopedic cushioning and support elements, reducing costs and process steps, enabling easy modification of mechanical properties and achieving consistent product quality with targeted damping and support functions in a single primary shaping step.
Implementation Method 1
The molding compound is cured on the carrier core, so that a carrier core, which is selectively cast in sections with the molding compound, is obtained as an integral molded part
Data Source
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AI summary
The method involves inserting a carrier core (22) into a casting tool, and introducing a plastic molding material (24) e.g. elastically hardening integral foam material and elastically hardening cell-free elastomer, into the casting tool. The carrier core is arranged in the casting tool such that a sealant prevents flow of the molding material around a surface section (28) of the carrier core. The molding material at the carrier core is allowed to harden, so that the carrier core is section-wise cast with the molding material. An independent claim is also included for a casting tool for producing a semi-elastic shaped part.