Flexible Prosthetic Socket With Edge-Bonded Rigid-Flexible Zones
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Solution Overview
Problem
Existing prosthetic sockets are heavy due to excessive use of flexible silicone material, which does not account for limb volume variations and require complex daily arrangement, leading to discomfort and potential loss.
Innovation Solution
A flexible medical appliance comprising a rigid structure with a deformable layer assembled edge-to-edge using a bonding fabric, reducing the need for sandwiched flexible material, and incorporating a carbon-based composite material for the rigid structure and elastomeric material for the deformable layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a socket comprises a rigid frame sandwiched by two layers of flexible silicone material, then the socket becomes flexible and adaptable to different stresses, but the socket becomes heavy due to the large amount of flexible material used
Solution Approach 1:
The socket is divided into distinct rigid and flexible zones rather than using a uniform structure. The rigid frame provides structural support while the flexible silicone layers are strategically positioned only where adaptability is needed, reducing overall material usage and weight.
Solution Approach 2:
Different parts of the socket have different properties - the frame is rigid for structural integrity while specific zones have flexible silicone coatings for comfort and adaptability. This localized application of materials optimizes both performance and weight.
2Strength
If a socket is made with rigid material, then the socket provides structural support, but the socket becomes uncomfortable in seated position due to its rigidity
Solution Approach 1:
The socket combines rigid materials for structural support with flexible silicone material in contact zones. The flexible zones provide comfort during seated positions while the rigid frame maintains overall structural integrity and support.
Solution Approach 2:
The socket uses a composite construction combining rigid structural material with flexible silicone material. This composite approach allows the socket to simultaneously provide structural support and comfort, resolving the contradiction between strength and ease of operation.
3Ease of operation
If a socket uses excessive flexible silicone material, then the socket becomes flexible and comfortable, but the socket becomes heavy and requires complex daily arrangement
Solution Approach 1:
The flexible silicone material is segmented and applied only in specific zones where flexibility and comfort are needed, rather than using excessive material throughout the entire socket. This reduces weight while maintaining comfort.
Solution Approach 2:
Flexible silicone material is applied locally in contact zones and areas requiring flexibility, rather than uniformly throughout the socket. This localized application provides comfort and flexibility while minimizing weight and simplifying daily arrangement.
Data Source
AI summary
A flexible medical appliance intended to be placed on a part of a patient's body and to match its shape comprises a rigid structure having a contour, as well as at least one deformable layer. The appliance further comprises a bonding fabric engaging at least one peripheral portion of the rigid structure extending along its contour, the rest of the bonding fabric forming an exposed portion for receiving the deformable layer. The rigid structure and the deformable layer are assembled edge to edge, the deformable layer completing the rigid structure to form the medical appliance. The present disclosure also proposes a method for manufacturing such an appliance.