Conformable Composite Precursor for Custom Orthosis
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Solution Overview
Problem
Current methods for creating custom orthotic devices using fiber-reinforced composites are labor-intensive, costly, and time-consuming, requiring multiple appointments and the use of expensive equipment like vacuum ovens or autoclaves, which limits efficiency and accessibility.
Innovation Solution
A curable, conformable composite precursor that can be manually shaped and cured in the desired form without external vacuum or pressure, using a conformable support structure and pre-impregnated fabric that can be thermoset through heating or UV radiation, allowing for single-day production of custom orthotic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional vacuum oven or autoclave curing methods are used, then the curable material achieves proper curing and structural integrity, but the process becomes costly, time-consuming, and requires expensive equipment
Solution Approach 1:
The curable composite precursor is designed to self-cure through its own chemical reaction (thermosetting or UV-curing) without requiring external vacuum or pressure equipment. The material itself provides the means for its own curing process, eliminating the need for costly vacuum ovens or autoclaves while maintaining proper structural integrity
Solution Approach 2:
The patent replaces the mechanical vacuum/pressure system with a chemical curing mechanism. Instead of using mechanical means (vacuum ovens, autoclaves) to achieve curing, the invention uses chemical reactions (thermosetting resins or UV-curable materials) that occur naturally under ambient conditions, substituting a complex mechanical system with a simpler chemical process
2Manufacturing precision
If conventional multi-appointment custom orthosis manufacturing is used, then the device achieves proper custom fit, but the production time extends over weeks and multiple appointments
Solution Approach 1:
The curable composite precursor is pre-formed and pre-packaged in a ready-to-use state before the patient appointment. The material is prepared in advance with proper impregnation and packaging, allowing the entire custom orthosis manufacturing process to be completed in a single appointment rather than requiring multiple weeks and several visits
Solution Approach 2:
The patent changes the curing parameters to occur at ambient temperature and pressure rather than requiring controlled vacuum/pressure environments. This parameter change enables the curing process to happen rapidly during a single appointment, reducing the overall production time from weeks to hours while maintaining custom fit accuracy
3Productivity
If the curable material is manipulated manually to desired shape, then the process becomes faster and simpler, but the material must retain its shape during curing without external support
Solution Approach 1:
The patent uses a flexible packaging material (such as a plastic bag or envelope) that encloses the curable composite precursor. This flexible shell maintains the desired shape of the material during curing by providing physical support and constraint, while still allowing the material to be manually manipulated into the required configuration before curing begins
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
Enables the rapid, cost-effective, and efficient creation of custom orthotic devices by allowing manual shaping and curing at ambient pressure, reducing production time and costs while maintaining high strength and stiffness.
Implementation Method 1
The fabric is impregnated with an uncured resin, thermoset or UV-curable, in which a conformable support structure supports the impregnated fabric
Implementation Method 2
The fabric is impregnated with an uncured resin, thermoset or UV-curable
Data Source
AI summary
The application discloses a conformable support structure for use in fiber composite precursor; a resin impregnated conformable fiber composite precursor, which may surround the support structure, for being manually manipulated and plastically deformed into a desired shape before being cured into a final product having the desired shape; the corresponding final product, which may be an orthosis or other product; and methods of making the final product or orthosis. The support structure is typically plastically deformable by hand to form the desired shape, may be substantially planar and may have various voids to promote controlled plastic deformation of the frame in one or more desired directions. The core may comprise a wire or tube and may include packing or filler material. The precursor includes a fiber layer impregnated with a thermoset resin and includes a compressor around the fiber layer. The fiber layer is supported internally or externally by the conformable support member. The precursor may be custom fitted to match the shape of an object and then thermally cured into a strong rigid product. The cured precursor can then be used to make a custom finished product.