Thermoplastic Cast with Foam Buffer Pad for Ventilation and Comfort
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Solution Overview
Problem
Conventional thermoplastic casts with mesh forms cause discomfort due to hard surfaces, poor ventilation, and increased inconvenience, especially when exposed to moisture, leading to pain and difficulty in bathing or showering.
Innovation Solution
A thermoplastic cast with a mesh structure and a buffer pad made of foam, where the foam is bonded to the structure using insert injection molding without adhesives, providing a Shore C hardness of 45 or less, and optionally covered with a rubber outer layer for additional cushioning and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a mesh form structure is used for the cast, then ventilation is improved, but the surface becomes hard and causes discomfort to the user
Solution Approach 1:
The cast combines a mesh form structure (providing ventilation) with a foam buffer pad layer (providing softness and comfort). This composite structure allows the cast to simultaneously achieve good ventilation through the mesh and comfort through the foam buffer, resolving the contradiction between ventilation and surface hardness.
2Object-affected harmful factors
If a lower pad is placed around the damaged area before the cast, then comfort is improved, but ventilation deteriorates and the pad becomes wet during showering
Solution Approach 1:
The foam buffer pad is integrated directly into the cast structure as an inherent component rather than being a separate lower pad. This merging eliminates the ventilation problem caused by separate pads while maintaining comfort, as the foam is directly bonded to the mesh structure and provides cushioning without trapping moisture.
3Strength
If adhesive is used to bond the foam buffer pad to the structure, then bonding strength is improved, but manufacturing complexity and environmental harm increase
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive) with a mechanical bonding method (insert injection molding). The foam buffer pad is injected directly into the mold cavity and mechanically interlocked with the mesh structure, eliminating the need for separate adhesive application steps and reducing manufacturing complexity while maintaining strong bonding.
4Reliability
If the cast is made to be durable and reusable, then durability is improved, but comfort may deteriorate due to hard surfaces
Solution Approach 1:
The cast uses a composite structure where the mesh form structure provides durability and structural integrity, while the foam buffer pad provides comfort and softness. This allows the cast to be both durable and comfortable, resolving the contradiction between durability and comfort.
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 cast provides improved comfort, ventilation, and durability by absorbing impacts and maintaining structural integrity, while allowing for easy cleaning and reuse, reducing user discomfort and inconvenience.
Implementation Method 1
absorb an impact applied to a damaged area
Implementation Method 2
The buffer pad may be bonded to the structure by insert injection molding without using an adhesive
Data Source
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AI summary
A thermoplastic cast according to an embodiment of the present invention includes a structure having a mesh form and a thermoplastic property, an outer cover provided on an outer surface of the structure, a buffer pad provided on an outer surface of the outer cover and having elasticity, and a finishing material provided on an outer surface of the buffer pad and configured to come into contact with a user's body. Melting points of the outer cover, the buffer pad, and the finishing material are higher than that of the structure. The finishing material has a porosity different from that of the buffer pad.