Prosthetic Foot Composite Layers Prevent Delamination

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Solution Overview

Problem

Existing methods for manufacturing composite articles, such as prosthetic feet, with varying dimensions result in delamination and noise due to the cutting of fibers, leading to product returns.

Innovation Solution

A method involving layers of fibrous material placed in a mold with a desired shape, where a polymer is impregnated and polymerized during a curing process, causing the fibers to realign and eliminate the need for cutting, thereby preventing delamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a block of composite article is manufactured first and portions are removed to achieve varied dimensions, then manufacturing flexibility is improved, but fiber cutting causes delamination and noise

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The mold is designed with the final desired shape before manufacturing, so the composite article is formed directly into the correct geometry during curing. This preliminary shaping action eliminates the need for subsequent cutting operations that would damage the fibers and compromise structural integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing approach changes from post-processing (cutting) to pre-processing (molded shaping). By changing the parameter of how the shape is achieved - from mechanical removal to formative molding - the fiber structure is preserved while still achieving varied dimensions.

Inventive Principle:

Principle #35Parameter changes

2Shape

If portions of the composite block are removed to achieve varied dimensions, then dimensional diversity is improved, but cutting fibers results in delamination

Engineering Contradiction:

Improvedimensional diversityVSAvoidlayer stability

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The mold is prepared with the precise final shape before the composite material is applied. This preliminary preparation ensures that the material is formed into the correct dimensions during curing, eliminating subsequent cutting that would destabilize the layered composition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical cutting process is replaced with a molding process where the shape is imposed through the mold geometry. This substitution eliminates the mechanical damage to fibers and layers that occurs during cutting, preserving composition stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If fibers are cut to achieve varied dimensions, then manufacturing adaptability is improved, but noise and delamination occur

Engineering Contradiction:

Improvedimensional adaptabilityVSAvoidnoise and delamination

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The desired dimensional variations are built into the mold before manufacturing begins. This preliminary shaping action allows the composite article to be formed with varied dimensions directly, eliminating the harmful effects of fiber cutting such as noise and delamination.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The harmful mechanical cutting process is replaced with a non-damaging molding process. The mold geometry imposes the required dimensional variations without mechanically disrupting the fiber structure, thereby eliminating noise and delamination.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach reduces manufacturing costs, minimizes waste, and enhances the structural integrity of the composite articles by preventing exposure of cut fibers, thus reducing delamination and noise.

Implementation Method 1

a first polymer impregnated with the plurality of layers of fibrous material and polymerized during a curing process

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS20250143894A1Prosthetic foot with layers of fibrous material

Publication Date: 2025.05.08 OSSUR ICELAND EHF

AI summary

A prosthetic foot including a continuous body extending from a proximal end to a distal end. The body includes an anterior surface, a posterior surface opposite the anterior surface, and a fin on the posterior surface. A prosthetic foot can include a first footplate and a second footplate. The first footplate extends between a proximal portion and a distal portion. The proximal and distal portions of the first footplate are configured to operatively engage a support surface during ambulation. The second footplate extends between a proximal portion and a distal portion. The distal portion of the second footplate is coupled to the first footplate at an intermediate location between the proximal and distal portions of the first footplate. The second footplate incudes an anterior surface, a posterior surface opposite the anterior surface, and a fin on the posterior surface.