Kydex Monolithic Plate Orthopaedic Corset
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Solution Overview
Problem
Existing orthopaedic corsets provide only partial support to the spinal column due to localized force distribution and lack of shared support among splints, leading to inadequate relief for nervous structures and potential muscle atrophy.
Innovation Solution
An orthopaedic corset featuring a floppy containment structure with a single-body plate made of Kydex, integrated into a pocket for secure attachment and optimized aeration, allowing for uniform load transmission and movement preservation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate splints are inserted into the fabric corset, then the spinal column receives support, but the force distribution is localized and the support function is not shared among all splints
Solution Approach 1:
The patent merges multiple separate splints into a single monolithic plate made of Kydex material. This unified structure distributes forces evenly across the entire spinal column rather than concentrating them at discrete points, resolving the contradiction between providing strong support and achieving uniform force distribution.
Solution Approach 2:
The patent uses Kydex, a composite material formed by co-molding thermoplastic polyolefin and thermoplastic elastomer, to create the monolithic plate. This composite material provides both the necessary rigidity for spinal support and the flexibility to conform to the body, enabling effective force distribution while maintaining support strength.
2Strength
If a rigid structure is used to support the spine, then compression on nervous structures is relieved, but flexibility and comfort are reduced
Solution Approach 1:
The patent changes the material parameters by using Kydex with specific thickness variations (3-5mm at the center, 1-2mm at the edges). This gradient in thickness allows the plate to be rigid enough for support where needed while remaining flexible and comfortable at the boundaries, resolving the contradiction between strength and ease of operation.
Solution Approach 2:
The patent applies different thicknesses of the same material at different locations on the plate. The central region has greater thickness for maximum support, while the peripheral regions have reduced thickness for comfort and flexibility. This local variation in quality resolves the contradiction between providing rigid support and maintaining flexibility.
3Ease of operation
If the fabric material is used for the corset, then comfort is improved, but the support function is insufficient due to the yielding nature of the fabric
Solution Approach 1:
The patent combines soft fabric material with a rigid Kydex monolithic plate in a composite structure. The fabric provides comfort and flexibility against the skin, while the Kydex plate provides the necessary rigid support. This composite approach resolves the contradiction between comfort and support function.
Solution Approach 2:
The patent merges the advantages of two different materials: the softness and comfort of fabric with the rigidity and force-distributing properties of the Kydex plate. This combination allows the corset to be both comfortable to wear and effective at supporting the spinal column.
4Force
If a single monolithic plate is used, then force distribution is optimized and support is shared across the spine, but manufacturing complexity increases
Solution Approach 1:
The patent uses injection co-molding technology to manufacture the Kydex monolithic plate as a single integrated piece. This manufacturing process, while specialized, efficiently produces the complex gradient-thickness structure in one step, resolving the contradiction between optimized force distribution and manufacturing ease.
Data Source
Figure 1~2
Figure 3
AI summary
Orthopaedic corset (1) for the support of the spinal column (10), comprising: - a floppy containment structure (2) adapted to be arranged stably around the torso of a user, - rear stiffening means (3) for stiffening said floppy structure (2), constrained to the latter, said rear stiffening means (3) comprising a plate (4) made of a single body, comprising at least one portion with a quadrangular extension (5) and having a central gap (6) with a longitudinal extension configured to be arranged overlapping with a portion of the user's spinal column (10), said plate being made of Kydex® and having a thickness comprised between 1 mm and 1.5 mm, said floppy structure (2) comprising a pocket (11) configured to contain said plate (4) made of a single body.