Segmented Thermal Pack for Curved Surface Conformability

Solution Overview

Problem

Conventional thermal packs with a single cell of material lack flexibility to conform to sharp anatomical curves, compromising heat transfer and comfort, while multi-cell packs may still fail to fit certain curved surfaces effectively.

Innovation Solution

A thermal pack design featuring first and second plastic sheets forming a sack with a flowable thermal material and a plurality of joint lines that maintain the material's placement, allowing for flexibility and preventing pooling, with joint lines arranged in patterns like tessellated shapes to create closed or open cells for optimal conformability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single cell of thermal material is used, then the pack structure is simple, but the pack lacks flexibility to conform to sharp anatomical curves

Engineering Contradiction:

Improvepack structureVSAvoidflexibility to conform to sharp curves

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The pack is divided into multiple cells separated by joint lines, allowing each cell to flex independently while maintaining structural simplicity. This segmentation enables the pack to conform to sharp anatomical curves without requiring complex materials or structures.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If less thermal material is used to increase flexibility, then the pack becomes more flexible, but the heat transfer functionality is compromised

Engineering Contradiction:

ImproveflexibilityVSAvoidheat transfer functionality

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The pack is divided into multiple cells separated by joint lines, allowing each cell to flex independently while maintaining structural simplicity. This segmentation enables the pack to conform to sharp anatomical curves without requiring complex materials or structures.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If a single cell design is used, then the pack structure is simple, but thermal material may pool in certain portions leaving other portions with little or no thermal material

Engineering Contradiction:

Improvepack structureVSAvoiduniform thermal material distribution

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The pack is divided into multiple cells separated by joint lines, allowing each cell to flex independently while maintaining structural simplicity. This segmentation enables the pack to conform to sharp anatomical curves without requiring complex materials or structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each cell contains a trapped body of thermal material that is localized and contained. This ensures uniform distribution of thermal material across the pack surface, preventing pooling in certain areas while maintaining adequate coverage in all regions.

Inventive Principle:

Principle #3Local quality

4Manufacturing precision

If multi-cell thermal packs are customized for specific anatomical features, then fit for those features is improved, but the pack may not conform well to other anatomical features

Engineering Contradiction:

Improvefit for specific anatomical featuresVSAvoidconformability to other anatomical features

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The pack design with joint lines and tessellated patterns creates a universally adaptable structure that can conform to various anatomical features without requiring customization. The modular cell structure allows the same pack design to effectively fit different body parts and curved surfaces.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 pack effectively conforms to curved surfaces, maintaining thermal contact even at acute bends and allowing greater flexibility without material pooling, enhancing heat transfer and comfort compared to single-cell and multi-cell designs.

Implementation Method 1

thermal packs are applied to anatomical forms and other curved surfaces for transferring thermal energy by way of a thermal material, such as a water, gel or clay, in the pack

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the joint lines serve to keep the flowable material in place... the joint lines inhibit the thermal material within the pack from flowing so freely within the pack as to result in the thermal material pooling at the pack edges

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11318042B2Thermal pack that conforms to curved surfaces

Publication Date: 2022.05.03 WEINSTEIN RANDY H

AI summary

The present disclosure is for a therapeutic thermal pack configured to conform to three dimensional surfaces. The therapeutic thermal pack comprises first and second plastic sheets bound together forming a sack. The sack further comprises a plurality of joint lines forming open or closed cells within the boundary of the sack. The open and closed cells are configured to enhance the flexibility of the sack. The sack contains a flowable thermal material within the open or closed cells.