Orthopedic Pad Assembly with Segmented Removable Layers
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Solution Overview
Problem
Existing orthopedic support pads are costly and complex, lacking versatility and adaptability to provide effective pressure relief over uneven surfaces, particularly for sensitive areas like incision sites or ulcerated appendages, without adding significant expense to orthopedic devices.
Innovation Solution
A conformable pad assembly with a first and second resilient layer, where removable sections are arranged in a pattern with edge clearances, allowing for permanent pressure relief areas to be created by tearing away the first layer, leaving a residual portion bonded to the second layer, which maintains structural integrity and can be easily replaced, and optionally combined with a rigid shell and strap for securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If removable sections are arranged in a pattern with edge clearances to provide pressure relief areas, then adaptability and customization are improved, but device complexity increases
Solution Approach 1:
The padding is divided into a first resilient layer and a second resilient layer, with the first layer containing removable sections that can be selectively removed to create pressure relief areas. This segmentation allows customization while maintaining a relatively simple overall structure.
Solution Approach 2:
Removable sections are extracted from the first resilient layer, allowing users to remove specific portions to create pressure relief areas over sensitive or ulcerated regions. This extraction approach enables adaptability without requiring a completely complex reconfigurable structure.
2Reliability
If a first resilient layer is laminated to a second resilient layer with removable sections, then pressure relief functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The removable sections are pre-formed and integrated into the first resilient layer during manufacturing, with edge clearances already defined. This preliminary preparation simplifies the manufacturing process by avoiding complex post-processing steps while ensuring reliable pressure relief functionality.
Solution Approach 2:
The padding uses a composite structure of two resilient layers laminated together, where the first layer contains removable sections and the second layer provides structural support. This composite approach achieves reliable pressure relief functionality while maintaining manufacturing simplicity through standard lamination processes.
3Ease of operation
If removable sections are made tearable from the padding, then ease of operation is improved, but structural integrity may be compromised
Solution Approach 1:
The first resilient layer is designed with local variations in properties: areas with removable sections have reduced bonding strength or pre-defined separation planes to enable easy tearing, while the overall structure maintains sufficient integrity through the second resilient layer and the bonding between layers at non-removable areas.
Solution Approach 2:
The first resilient layer is segmented into removable sections separated by edge clearances, allowing these sections to be torn away easily. The segmentation creates natural separation zones that facilitate easy removal while the remaining structure maintains structural integrity through the second layer.
4Ease of repair
If the padding is designed to be disposable and replaceable, then ease of repair and hygiene are improved, but cost increases
Solution Approach 1:
The padding is designed as a disposable component that can be easily replaced rather than repaired. By using cost-effective resilient materials and a simple laminated structure with removable sections, the padding achieves ease of replacement while minimizing cost, making disposable use economically acceptable.
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 solution provides a cost-effective, adaptable, and disposable padding system that effectively forms pressure relief areas without compromising structural integrity, allowing for easy replacement and customization of pressure relief zones, suitable for various anatomies and applications.
Implementation Method 1
a first resilient layer and a second resilient layer underlying and laminated to the first layer
Data Source
Figure 1~3
Figure 4~6
AI summary
A pad assembly (10) comprises a padding (12) defining first and second surfaces (18, 20), and includes a first layer (42) being resilient and accessible from the first surface (18) and a second layer (44) being resilient and underlying and secured to the first layer (42). First and second removable sections (36) are formed from at least one of the first and second layers (42, 44) and are arranged in a pattern and separated by edge clearances (38). Each of the first and second removable sections (36) is tearable from the padding (12) such that a residual portion (56) of the removable section (36) remains when at least one of the first and second removable sections (36) is removed from the padding (12). The pad assembly (10) may include a strap (16), and a substantially rigid or rigid shell (14) connecting to the padding (12) and strap (16).