Prosthetic Sock Distal Fabric Disc Reinforcement
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Solution Overview
Problem
Prosthetic socks with knitted fabric often have loose threads that can jam the prosthetic lock due to their design, and previous solutions like gluing around the channel cause discomfort and distal thickness issues.
Innovation Solution
A prosthetic sock with a fabric disc at the distal end that includes a channel for the prosthetic, where the fabric disc has a complementary disc channel and is attached using a heat-activated polyurethane adhesive, eliminating the need for glue on the interior rim.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glue is applied around the open channel in the sock to prevent loose threads, then thread containment is improved, but the glue becomes hard and bulky upon drying causing patient discomfort and distal thickness stacking
Solution Approach 1:
The patent changes the physical state and material properties of the adhesive from conventional fabric glue to heat-activated polyurethane adhesive. This parameter change allows the adhesive to remain flexible and soft after curing, eliminating the hard and bulky characteristics that caused patient discomfort while maintaining effective thread containment at the sock distal end.
Solution Approach 2:
The patent uses a composite material approach by combining heat-activated polyurethane adhesive with the knitted fabric structure. This composite solution provides both the thread containment function and the flexibility needed for patient comfort, resolving the contradiction between reliability and ease of operation.
2Reliability
If glue is applied around the open channel to secure threads, then thread containment is improved, but distal thickness stacking occurs creating up to a quarter of an inch growth that pushes the patient out of the socket
Solution Approach 1:
The patent changes the adhesive parameters from conventional glue to heat-activated polyurethane adhesive with controlled application. This allows the adhesive to cure flat and thin, preventing distal thickness stacking while maintaining thread containment effectiveness.
3Strength
If a fabric disc is applied to the distal end to reinforce the sock, then structural strength is improved, but the attachment process must avoid creating bulk or discomfort
Solution Approach 1:
The patent applies heat-activated polyurethane adhesive to attach the fabric disc, changing the adhesive parameters to ensure flexible, bulk-free bonding. This provides strong reinforcement at the distal end while maintaining patient comfort through the flexibility and thin profile of the cured adhesive.
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 prevents jamming of the prosthetic lock and reduces discomfort by maintaining a secure fit without adding bulk, ensuring a stable and comfortable engagement with the prosthetic.
Implementation Method 1
The fabric disc is attached to the distal end using a heat activated polyurethane adhesive layer
Data Source
AI summary
A sock comprising an outer fabric layer that tapers from a proximal end down to a distal end. The distal end of the sock further comprises a fabric disc which can be mechanically or chemically applied to the outer fabric layer. The distal end of the sock further comprises a channel which allows for the receipt of a prosthetic (not illustrated). Likewise, the fabric disc comprises a complementary disc channel which allows for the receipt of a prosthetic. No glue is present on the interior rim of the channel or the interior disc rim of the disc channel. Preferably the fabric disc is made of polyester but may be made of any material that has a horizontal stretch that is at least 20% less than that of the exterior fabric layer. Further, the fabric disc preferably has an outer diameter between ½ and 2 inches and an inner diameter between ¼ to ½ inches. The fabric disc is attached to the distal end using a heat activated polyurethane adhesive layer but may be applied using fabric glue as well.