Moisture-Resistant Orthopedic Cast with Phase-Changing Splint
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Solution Overview
Problem
Conventional bone fracture treatment methods require multiple devices and interventions, leading to inefficiencies in moisture management, fit, and cost, as well as increased patient inconvenience due to the need for frequent device changes during different treatment phases.
Innovation Solution
A moisture-resistant multi-phase orthopedic system comprising a sleeve with a moldable splint and removable cast, utilizing a moisture-impervious material and a reactive system that hardens upon exposure to moisture, along with a soft, conformable fabric for enhanced moisture transfer, allowing the same device to be used throughout treatment phases with improved fit and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional casting and splinting methods are used with multiple devices for different treatment phases, then the treatment can address different stages of fracture healing, but the patient must undergo frequent device changes and incur higher costs
Solution Approach 1:
The patent applies universality by designing a single orthopedic device that can function across multiple treatment phases. The cast/splint system is engineered to provide acute phase immobilization, sub-acute support, and rehabilitation assistance without requiring removal and replacement, thereby reducing the number of devices needed while maintaining adaptability to different healing stages
Solution Approach 2:
The patent implements dynamics through a progressive transition system where the device evolves from a rigid acute phase cast to a more flexible rehabilitation support structure. The cast can be modified in-place by removing portions of the rigid outer layer to reveal and activate a flexible inner splint layer, allowing the device to dynamically adapt to changing treatment requirements
2Reliability
If conventional plaster or synthetic casts are used, then the fracture can be immobilized during acute phase, but moisture retention occurs causing skin maceration and discomfort
Solution Approach 1:
The patent applies composite materials by combining a rigid outer cast layer with a flexible inner splint layer, where each layer serves specific functions. The outer layer provides immobilization while the inner layer manages moisture through its breathable properties, creating a composite structure that addresses both immobilization effectiveness and moisture control
Solution Approach 2:
The patent implements local quality by giving different regions of the device different properties - the outer cast layer has rigid, moisture-resistant properties for immobilization, while the inner splint layer has flexible, breathable properties for moisture management and comfort, with each layer optimized for its specific function
3Reliability
If multiple casting and splinting procedures are performed during treatment, then the fracture can be properly managed through different phases, but the cost and patient inconvenience increase significantly
Solution Approach 1:
The patent implements continuity of useful action by designing a device that remains in place throughout the entire treatment process from acute phase through rehabilitation. The cast can be progressively modified in-place rather than removed and replaced, maintaining continuous support and immobilization while eliminating the downtime and inconvenience of multiple device changes
4Strength
If a rigid cast is used for acute phase immobilization, then the fracture can be stabilized, but the device cannot be reused or adapted for subsequent treatment phases
Solution Approach 1:
The patent applies segmentation by dividing the device into distinct functional layers - a rigid outer cast layer for immobilization and a flexible inner splint layer for long-term support. This segmentation allows the rigid layer to be removed or modified while the flexible layer remains in place, enabling the device to transition from acute phase to rehabilitation phase without complete replacement
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 effectively manages moisture, ensures a proper fit throughout treatment phases, reduces the need for frequent device changes, and provides cost-saving, efficient, and medically effective casting and splinting procedures.
Implementation Method 1
a reactive system impregnated into or coated onto the substrate that remains stable when maintained in substantially moisture-free conditions and hardens upon exposure to sufficient moisture to form a rigid, self supporting structure
Implementation Method 2
a moldable splint positioned in the sleeve and sealed therein against entry of moisture until use
Implementation Method 3
formed of a moisture resistant, single layer, three-dimensional double knit fabric having an open structure for providing enhanced moisture transfer from the skin of the patient outwardly into the atmosphere
Data Source
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AI summary
A moisture-resistant multi-phase orthopedic system including a moisture-impervious sleeve, a moldable splint including a covered resin- Impregnated substrate, an elongate wrap for retaining the splint on the limb, and a removable cast for application to the limb during subsequent treatment phase Including a cast body having interior side and exterior side and comprising a fabric having an open structure for providing enhanced moisture transfer away from the skin and a movable flap carried by the body overlying a part of the cast body to be applied to a treatment area of the limb, the flap adapted to cover and retain between the cast body and the flap the splint worn by the patient during the initial treatment phase in the same position as the location of the splint during the initial treatment phase. A method of immobilizing a limb in multiple treatment phases utilizing the orthopedic system.