Vented Total Contact Cast with 3D Fabric Spacers

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Solution Overview

Problem

Current methods for treating diabetic foot ulcers using total contact casts are time-consuming, costly, and often ineffective in offloading weight from open wounds, while also causing suffocating pressure that can lead to burns during removal.

Innovation Solution

An orthopedic total contact cast system that includes two or more fiberglass cast rolls, sterilized cotton, a tubular stockinette, and compressible 3D fabric spacers to absorb edema pressure and provide ventilation to the wounded leg.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional total contact cast application methods are used, then weight offloading from the wound is achieved, but the application process is time-consuming and costly

Engineering Contradiction:

Improveweight offloading effectivenessVSAvoidapplication time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The cast system is divided into multiple modular components including pre-cut foam inserts, stockinette layers, and cast material sections that can be independently prepared and assembled, enabling faster application while maintaining weight offloading effectiveness

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Components such as foam inserts and stockinette are pre-prepared and pre-cut to the required sizes before patient application, eliminating time-consuming on-site preparation and reducing overall application time while ensuring proper fit for effective weight distribution

Inventive Principle:

Principle #10Preliminary action

2Force

If traditional total contact cast is applied, then weight support is provided, but the cast is hard to put on and take off

Engineering Contradiction:

Improveweight support capabilityVSAvoidapplication and removal ease

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The cast is constructed from segmented components including separate foam inserts, stockinette layers, and cast material sections that can be independently manipulated during application and removal, making the process easier while maintaining structural weight support

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cast system incorporates flexible foam inserts and layered construction that allow dynamic adjustment during application and facilitate easier removal by enabling controlled separation of components without compromising the weight-bearing structural integrity

Inventive Principle:

Principle #15Dynamics

3Force

If traditional total contact cast is used, then weight distribution is achieved, but the cast is non-breathable and causes suffocating pressure

Engineering Contradiction:

Improveweight distributionVSAvoidsuffocating pressure and lack of ventilation

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The cast incorporates porous foam inserts and breathable fabric layers that allow air and fluid permeation, providing ventilation to the underlying skin while maintaining the weight distribution function through the structured layered construction

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The cast system uses composite construction combining breathable fabrics, porous foam materials, and structural cast components in layers, achieving both weight distribution through the rigid outer structure and ventilation through the breathable inner layers

Inventive Principle:

Principle #40Composite materials

4Reliability

If traditional total contact cast is applied, then wound offloading is achieved, but edema pressure builds up inside the cast

Engineering Contradiction:

Improvewound offloading effectivenessVSAvoidinternal edema pressure

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

Porous foam inserts and breathable layers allow edema fluid to escape through the cast structure, reducing internal pressure buildup while maintaining the offloading function through the external structural support of the cast

Inventive Principle:

Principle #31Porous materials

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 system allows for quicker and simpler application of the total contact cast, effectively offloads weight from the wound, reduces internal edema pressure, and provides atmospheric aeration, thereby improving patient comfort and rehabilitation outcomes.

Implementation Method 1

a body of three dimensional (3D) fabric spacer material forming therein a pathway for air flow from an ambient environment to the patient's leg

Methodology Applied

Scientific EffectAir flow through porous material: Porosity

Implementation Method 2

A series of compressible 3D fabric spacers to absorb the edema pressure

Methodology Applied

Scientific EffectCompression and absorption: Compression

Implementation Method 3

one or more adhesive areas on a common side of the ventilation member and removably covered for adhesively mounting to the stockinette

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20250049615A1Quick application of vented total contact cast

Publication Date: 2025.02.13 BARBERIO ALESSANDRO

AI summary

A vented total contact cast for a wound on a patient's leg features ventilation members in the form of adhering, compressible flexible and ventilating 3D fabric spacers with release liners which cover an adhesive configured for attaching to a stockinette to be received over the patient's leg. The ventilation members may be provided in sets of different shapes and different dimensions, for selective mounting to the stockinette based on the area of the leg to be aerated and the size of the leg.