Functional Cast Kit with Moisture-Curable Resin Tape
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Solution Overview
Problem
Conventional cast systems require multiple components, leading to inefficiencies in application, waste, and increased costs due to the need for on-site assembly and lack of pre-fabricated, pre-sized kits, which complicates the application and adjustment of functional casts.
Innovation Solution
A functional cast kit containing pre-fabricated components such as conformable cast tape, liner, straps, and edger material, packaged in a box, allowing for efficient application and customization of casts without waste, including moisture-curable resin tape that hardens upon exposure to water, and touch fastener materials for securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional cast systems use multiple separate components, then flexibility in component selection is improved, but application efficiency and waste reduction deteriorate
Solution Approach 1:
The patent combines multiple cast components (liner, cast tape, edger material, straps) into a single integrated kit that is pre-assembled and packaged together. This merging eliminates the need for technicians to gather separate components from different locations, significantly improving application efficiency while reducing waste through precise pre-sizing of each component.
2Productivity
If components are pre-fabricated and sized in a kit, then application efficiency and waste reduction are improved, but device complexity increases
Solution Approach 1:
The kit is segmented into distinct, pre-fabricated components (liner, cast tape, edger material, straps) that are individually packaged within the kit. This segmentation allows for precise sizing of each component to match specific patient needs while maintaining the benefits of pre-assembly, effectively managing complexity through modular organization.
3Reliability
If cast tape is stored in moisture-proof pouches, then material integrity is improved, but activation time deteriorates
Solution Approach 1:
The cast tape is pre-cut to specific lengths and pre-packaged in moisture-proof pouches within the kit, eliminating the need for on-site cutting and reducing activation time. The preliminary packaging preserves material integrity while the pre-cut configuration ensures rapid deployment when needed.
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 kit enables efficient, waste-free application and adjustment of functional casts, reducing the need for multiple components and on-site assembly, while maintaining flexibility and ease of use, thus improving the therapeutic outcome and reducing costs.
Implementation Method 1
a length of cast tape of the type impregnated with a moisture-curable resin that remains in a flexible, comformable state until activated and hardened into a rigid state by exposure to moisture
Data Source
AI summary
A kit for containing components for fabricating functional casts, and including a box, and a length of liner for being placed next to the skin of the body part to be immobilized; a moisture-proof package containing a length of cast tape of the type impregnated with a moisture-curable resin that remains in a flexible, comformable state until activated and hardened into a rigid state by exposure to moisture; at least one strap for securing the cast onto the body part being immobilized and a length of adhesive edger material for enclosing raw edges of the hardened cast tape for protecting the skin of the cast wearer from exposure to the cast tape, each of which is contained in the box.