Custom Cervical Collar Brace Using Heat-Molded Polyethylene Blanks

Solution Overview

Problem

Existing neck braces often fail to provide a customized fit, leading to discomfort and inadequate support, as they are not tailored to individual patients' specific measurements.

Innovation Solution

A method and kit for creating a custom-fabricated cervical collar brace by measuring a patient's neck area, using adjustable model components, and heat-molding blanks to form a personalized neck brace that can be trimmed and padded for a precise fit, incorporating Velcro and other securing mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If standardized neck braces are used, then manufacturing cost and device complexity are reduced, but fit accuracy and patient comfort deteriorate

Engineering Contradiction:

Improvefit accuracyVSAvoidcustomization process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The model is divided into multiple adjustable components including neck blocks of different heights and widths, chest base sections, and modular positioning elements. This segmentation allows the model to be customized to match various patient anatomies while using standardized manufacturing processes for each component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The kit enables adjustment of key anatomical parameters such as neck height, neck width, and chest dimensions by selecting and combining different sized components. This parameter adjustment capability allows the model to be adapted to individual patient measurements without requiring completely custom-manufactured braces.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If custom-fabricated neck braces are made for each patient, then fit accuracy and comfort are improved, but manufacturing time and productivity are reduced

Engineering Contradiction:

Improvecustom fit accuracyVSAvoidbrace manufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

A pre-configurable model is prepared in advance with adjustable components that can be quickly assembled to match patient measurements. This preliminary model preparation enables rapid customization of the neck brace to the specific patient anatomy, significantly reducing the time required compared to traditional custom fabrication methods.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The model components are designed with universal interfaces and standardized dimensions that allow the same set of components to be used across multiple patients with different anatomies. This multi-functionality enables the kit to serve as a universal customization system rather than requiring patient-specific manufactured parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If adjustable model components are used, then adaptability to different patient sizes is improved, but device complexity and initial cost are increased

Engineering Contradiction:

Improvepatient size adaptabilityVSAvoidmodel component complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The model is divided into multiple adjustable components including neck blocks of different heights and widths, chest base sections, and modular positioning elements. This segmentation allows the model to be customized to match various patient anatomies while using standardized manufacturing processes for each component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The model components are designed with universal interfaces and standardized dimensions that allow the same set of components to be used across multiple patients with different anatomies. This multi-functionality enables the kit to serve as a universal customization system rather than requiring patient-specific manufactured parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution allows for a tailored neck brace that provides improved comfort and support by accurately matching the patient's anatomy, enhancing the fit and functionality of the brace.

Implementation Method 1

The blank being transformable to a final configuration different from the initial configuration when the blank is placed onto at least the neck portion of the model and heated

Methodology Applied

Scientific EffectHeat molding: Heating

Implementation Method 2

the blank being formed of a material that is malleable when heated to a predetermined temperature

Methodology Applied

Scientific EffectThermal softening:

Implementation Method 3

heating the front blank (and then separately the back blank) with a heating device

Methodology Applied

Scientific EffectThermal energy transfer: Heating

Data Source

PatentUS9687380B1Cervical collar brace kit, collar blanks, methods of forming a model of a patient, and methods of forming collar blanks

Publication Date: 2017.06.27 FALK DAVID L

AI summary

A kit for modeling a patient's neck area and creating a neck brace that is sized specifically for an individual patient. Combinations of components are chosen to build the model according to the actual measurements of the patient. A front and back blank are molded to correspond to the model, typically by heat molding. Once cooled, the blanks are removed from the model and Velcro®, padding, and a Velcro® strap are added to form a custom cervical collar brace. The front and back blanks can be formed on preformed blank molds, or can involve a method of forming blank molds upon which front or back blanks or both can be formed. The method can involve applying a material, such as low density polyethylene, to the blank mold and conforming the material to the mold. The blank can then be cut from the material, typically along an outline or contours.