Thermoplastic Cast Material Web Wound on Template for Orthopedic Splint
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Solution Overview
Problem
Thermoplastic cast materials for orthopedic splints require a minimum thickness for rigidity and stability, making them difficult to handle and store, and result in waste and high costs due to the need for multiple sizes and complex handling procedures.
Innovation Solution
A system using a thermoplastic cast material available as a flat material web, wound around a template to achieve the required thickness, which can be easily activated for deformability and adapted to different body parts, eliminating the need for multiple sizes and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic cast material is used to ensure rigidity and stability, then the splint achieves sufficient structural strength, but the material becomes difficult to handle and store due to high flexural rigidity in the non-activated state
Solution Approach 1:
The cast material is divided into multiple thin layers that can be individually handled and stacked. Each layer maintains flexibility for easy handling, while the combined stack achieves the required thickness and rigidity when activated, resolving the contradiction between individual layer handleability and final product strength.
Solution Approach 2:
The material's physical state is changed through temperature activation. In the non-activated state, the material remains flexible and easy to handle. Upon heating to the activation temperature, the material undergoes a phase transition that provides the necessary rigidity and stability for the finished splint, allowing the same material to satisfy both handling and structural requirements at different stages.
2Strength
If sheets of specified thickness are used to ensure rigidity, then the splint achieves sufficient structural strength, but waste increases when adapting to small limbs and joints while sheets may be too small for extra-long body parts
Solution Approach 1:
Instead of using pre-cut sheets of fixed thickness, the invention uses multiple thin layers that can be stacked to achieve the required thickness. This segmentation allows precise adaptation to different body parts - small limbs use fewer layers, while extra-long body parts use more layers, eliminating the material waste associated with using fixed-thickness sheets for various applications.
Solution Approach 2:
The system transitions from static pre-cut sheets to a dynamic stacking approach where the number of layers can be adjusted based on the specific application requirements. This dynamic configuration allows optimal material utilization for different limb sizes and lengths, reducing waste while maintaining the necessary structural strength.
3Ease of manufacture
If water hardening polyurethane systems are used, then the dressing material can be professionally applied and adapted to the body, but moisture-free production and complex water-impervious packaging are required
Solution Approach 1:
The invention employs thermoplastic cast material that does not require water-impervious packaging, simplifying the packaging system. The material can be stored and handled in standard packaging without complex moisture barriers, reducing packaging complexity while maintaining professional applicability through its thermoplastic activation mechanism.
4Ease of manufacture
If polyurethane resins are used for water hardening, then the dressing material can be applied professionally, but storage stability is comparatively low even under maximum moisture-free conditions
Solution Approach 1:
The thermoplastic cast material eliminates the storage stability issues associated with polyurethane resins by using a different activation mechanism. The material remains stable during storage and only undergoes the necessary physical changes when heated for activation, providing both professional applicability and long-term storage stability without the degradation problems of water-hardening systems.
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
Simplifies the production of orthopedic splints by allowing for customizable thickness and stability, improved storage stability, and cost-effectiveness, as the thermoplastic material can be stored without water vapor impermeable wrapping and activated as needed.
Implementation Method 1
the self-adhesive properties are achieved by heating the thermoplastic plastic to or above the respective softening temperature
Implementation Method 2
The material again hardens on cooling, in which case it may still be molded at temperatures below the melting point for some time
Data Source
AI summary
The disclosure relates to a system for producing an orthopedic splint made of a cast material, wherein the system includes at least one thermoplastic cast material present as a flat material web and a template having a flat template body, wherein the cast material can be wound around the template body in a prescribed direction for generating a splint blank, and the splint blank can be activated in order to achieve deformability, particularly after cutting the cast material to length, and to a method for producing an orthopedic splint.