Orthosis Fastening Elements Embedded in Fiber Composite
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Solution Overview
Problem
Current methods for producing orthosis or prosthesis components are inefficient and costly, lacking simplicity and safety in fastening joint and functional components, and often require additional fixing devices during production.
Innovation Solution
A method involving a base layer shaped to match the body part, with fastening elements having form-fit elements that allow for secure attachment of further components, using a fiber composite material layer that embeds the base layer for stability and accessibility of form-fit elements, enabling easy adaptation and secure mounting of joint devices without external fixing devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional fixing devices (dummies or space holders) are used to hold fastening elements in position during production, then the orthosis components can be produced with proper orientation, but the device complexity and manufacturing cost increase
Solution Approach 1:
The method performs preliminary positioning of fastening elements by arranging them on a support corresponding to the body part shape before applying the fiber-reinforced plastic material. This preliminary arrangement ensures correct orientation and position of fastening elements without requiring complex external fixing devices during the curing process, thereby reducing device complexity while maintaining manufacturing precision
Solution Approach 2:
The support structure serves multiple functions: it provides the base for positioning fastening elements, maintains their orientation during material application, and acts as the final form for the orthosis component. The support itself becomes part of the finished product, eliminating the need for separate external fixing devices that would need to be removed or remain in the final product
2Reliability
If fastening elements are embedded in the fiber composite material, then secure attachment of joint devices is achieved, but the form-fit elements must remain accessible for assembly
Solution Approach 1:
The fiber-reinforced plastic material is applied selectively around the bases of fastening elements to provide embedding and secure attachment, while deliberately leaving the form-fit elements (protruding parts) accessible. This local differentiation ensures that different parts of the same structure serve different functions: embedded portions provide security while exposed portions provide accessibility for assembly operations
3Stability of the object's composition
If the base layer is made with great inherent stability, then it maintains shape during handling, but it may be difficult to conform to the body part shape initially
Solution Approach 1:
The base layer is prepared in advance with appropriate stability characteristics before being applied to the support. The material is selected and pre-treated to ensure it has sufficient inherent stability to maintain shape during subsequent handling and curing operations, while still being capable of conforming to the body part shape when first applied to the support structure
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
This method simplifies and cost-effectively produces orthosis or prosthesis components with improved stability and ease of assembly, allowing for individual adaptation and secure fastening of joint devices, enhancing wearing comfort and production efficiency.
Implementation Method 1
The at least one layer of a fiber composite material, for example of a prepreg, is applied to the base layer and the base embedded, wherein the form-fit element remains accessible from the side facing away from the base layer. The at least one layer of a fiber composite material is then cured
Data Source
AI summary
A method for producing orthosis or prosthesis components for receiving or for fastening to a body part, the method including: applying a base layer to a support corresponding in form to the form of the body part, arranging multiple fastening elements having a base and an interlocking element protruding from the base, on the base layer in defined positions relative to one another, the base of the fastening element resting on the base layer or facing towards the base layer, placing at least one layer of a fiber composite material on the base layer and embedding the base, the interlocking element remaining accessible from the side facing away from the base layer, and curing the at least one fiber composite material layer.