Textile Orthopedic Aid Plastic Functional Element Connection
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Solution Overview
Problem
Existing textile orthopedic aids with integrated plastic functional elements face limitations in transferring mechanical properties effectively to the base body due to non-direct connections, leading to reduced functionality and complex manufacturing processes.
Innovation Solution
A textile part with a functional element and fastening element connected in a form-fitting and cohesive manner, using materials that can be bonded via plastic welding or injection, allowing for a strong and efficient transfer of mechanical properties to the base body through a single process step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the functional element is connected to the base body via a support element (carrier element) only, then the manufacturing process is simplified, but the functionality is reduced because the functional properties are not directly transferred to the base body
Solution Approach 1:
The patent combines both connection methods (direct cohesive connection and positive connection via support element) into a single integrated structure. The functional element is connected to the base body both directly through cohesive bonding and indirectly through the support element with positive geometric interlocking, merging the advantages of both approaches to achieve full functionality transfer while maintaining manufacturing efficiency
2Strength
If the functional element is welded onto the base body via a plastic-laminated support element in two process steps, then the connection is secure, but the manufacturing process becomes complex
Solution Approach 1:
The patent merges two separate manufacturing steps (applying the support element and then welding the functional element) into a single integrated process. The support element is applied to the base body and the functional element is connected to it in one continuous operation, reducing process complexity while maintaining connection strength through the combination of cohesive and positive connections
Solution Approach 2:
The support element is pre-formed with the necessary positive connection geometries (protrusions and recesses) before being applied to the base body. This preliminary preparation of the connection interface allows for rapid assembly and reduces the complexity of the overall manufacturing process while ensuring secure mechanical interlocking
3Ease of manufacture
If only a cohesive connection is used between the functional element and the base body, then the manufacturing process is simple, but the transfer of mechanical properties and stabilizing effect is reduced
Solution Approach 1:
The patent employs a composite connection strategy combining two different connection mechanisms (cohesive bonding and positive mechanical interlocking) to create a hybrid connection system. This composite approach leverages the advantages of both methods: the simplicity and broad applicability of cohesive bonding plus the superior mechanical property transfer of positive connection, achieving enhanced force transmission while maintaining manufacturing efficiency
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 enhances the stability and functionality of the textile part by ensuring a strong connection between the functional element and the base body, improving the transfer of mechanical properties and simplifying the manufacturing process.
Implementation Method 1
supplying energy causes a local melting or softening of the plastic material
Implementation Method 2
supplying energy, for example in the form of high-frequency or ultrasonic vibrations
Implementation Method 3
welded exclusively in the area of the carrier element, which is wider than the functional element, which is done by melting the plastic coating of the carrier element
Data Source
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Figure 8~10
AI summary
Textile part, in particular a textile orthopedic aid, comprising a textile base body (2) and at least one functional element (5) made of plastic arranged on the base body (2), wherein the functional element (5) is connected either positively or positively and materially to at least one fastening element (4) and the fastening element (4) is materially connected to the base body (2).