Inverted Waterproof Cast Liner With Thermal Seal
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Solution Overview
Problem
Current waterproof cast options are limited and ineffective, as they either fail to provide a secure seal when submerged or require additional training and cuts to fit muscle curvatures, and they are not amenable to standard non-waterproof casting techniques.
Innovation Solution
A waterproof cast liner system comprising an inverted waterproof cast sleeve with a hydrophilic padding layer and a permeable membrane, allowing for a secure seal and compatibility with conventional casting techniques, using a thermal bond or adhesive for sealing and a support layer to prevent stretching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If waterproof bags are used to cover the limb, then waterproof protection is provided, but the seal breaks under water pressure
Solution Approach 1:
The waterproof cast liner system uses nested layers where an inner waterproof layer is placed within an outer waterproof layer. The inner layer provides the primary seal against water penetration, while the outer layer reinforces protection. This nested structure distributes water pressure across multiple layers rather than relying on a single seal, preventing seal breakdown under pressure while maintaining reliable waterproof protection.
2Shape
If padded material is used to fit muscle curvature, then the cast fits limb curves, but additional cuts and training are required
Solution Approach 1:
The waterproof cast liner system employs dynamic, flexible materials that can elongate and conform to complex limb curvatures including muscle contours, thumb, and wrist areas. The material's inherent elasticity and flexibility allow it to stretch and mold to the limb's shape without requiring cuts or complex manipulation, significantly reducing application complexity while maintaining excellent fit to limb curvature.
3Ease of manufacture
If conventional wrapping techniques are used, then standard casting procedures are followed, but waterproof sealing is compromised
Solution Approach 1:
The waterproof cast liner system segments the waterproofing function into a separate, pre-formed liner component that is applied before the conventional cast. This segmentation allows the waterproof sealing function to be independent from the casting procedure, enabling standard wrapping techniques to be used for the cast application while the pre-formed liner maintains waterproof integrity. The liner acts as a self-contained waterproof barrier that does not interfere with conventional casting methods.
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 system provides a reliable waterproof seal under water pressure while allowing perspiration to pass through, ensuring comfort and ease of application, with the ability to fit complex limb curvatures without additional training or cuts.
Implementation Method 1
A waterproof cast sleeve may also be permeable to gases which will allow perspiration to pass through the waterproof cast sleeve. An exemplary waterproof cast sleeve comprises a permeable membrane, such as expanded polytetrafluoroethylene (ePTFE), membrane.
Implementation Method 2
The extended end is pull back over the inner layer of the waterproof cast sleeve and a seal is produced between the inside and outside layers to produce a waterproof enclosure around the padding layer.
Implementation Method 3
An exemplary waterproof cast sleeve comprises a waterproof layer, or a waterproof material that has a water entry pressure of about 16.9 kPa or 1 psi or more, when exposed to said water entry pressure for one minute.
Data Source
AI summary
A waterproof cast liner is formed by inverting a waterproof cast sleeve over a padding material and sealing the inner and outer layers together to produce a waterproof cast. The padding material is retained within the waterproof enclosure formed by the inverted and seal liner and a rigid material is configure around the outer layer of the inverted sleeve and the limb to form a waterproof cast. A waterproof cast sleeve may have an appendage conduit that branches from the sleeve conduit to enable an appendage such as a thumb or finger to extend out from the waterproof cast. The inner and outer layer of the inverted sleeve or waterproof liner are sealed together to produce a waterproof enclosure for the padding material. The seal may include a thermal seal or adhesive and the rigid material of the cast may form an adhesive for the seal.