Welded Sheet Heating Blanket for Surgical Patient Warming

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Solution Overview

Problem

Conventional forced-air warming systems for surgical patients are costly, noisy, potentially contaminating, and pose risks of burns due to high temperatures, and their components, such as stitching and rivets, are difficult to clean and disinfect, leading to microbial contamination.

Innovation Solution

A flexible electric heating blanket with a waterproof shell made from welded sheets of flexible material, incorporating a conductive fabric heating element and a temperature sensor assembly, which provides uniform heat distribution and is easy to clean, eliminating the need for perforating fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional forced-air warming systems are used, then patient warming effectiveness is improved, but device complexity and cost increase

Engineering Contradiction:

Improvepatient warming effectivenessVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical forced-air system (blower, hoses, air distribution network) with a simple electrical heating element system. The heating blanket uses electrical resistance heating elements embedded in a flexible blanket structure, eliminating the need for mechanical air movement components while achieving effective patient warming through direct thermal contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the unnecessary complex components (blower motor, air hoses, control valves) from the warming system, retaining only the essential heating function through simplified electrical heating elements and insulation layers.

Inventive Principle:

Principle #2Taking out (Extraction)

2Temperature

If forced-air warming systems are used, then patient warming effectiveness is improved, but noise and contamination risks increase

Engineering Contradiction:

Improvepatient warming effectivenessVSAvoidnoise and contamination

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the noisy mechanical blower system with silent electrical heating elements, eliminating noise generation. It also eliminates the air hose system that could contaminate the surgical field, using instead a clean electrical blanket system that generates heat without moving air or requiring hoses that could introduce contaminants.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If reinforced seals with stitching and rivets are used, then shell strength and reliability are improved, but ease of cleaning deteriorates

Engineering Contradiction:

Improveshell strengthVSAvoidease of cleaning

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces mechanical fastening methods (stitching, rivets, grommets) with adhesive bonding to seal the shell layers. This substitution eliminates holes and crevices in the shell structure, creating a smooth continuous surface that can be easily cleaned and disinfected without trapping contaminants in fastener holes or thread gaps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If high temperature air is used in forced-air warming, then patient warming effectiveness is improved, but safety deteriorates due to burn risks

Engineering Contradiction:

Improvewarming effectivenessVSAvoidburn risk

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the high-temperature forced air system with electrical resistance heating elements that provide controlled, distributed heat directly through the blanket. This eliminates the need to heat air to dangerous temperatures, as the heating elements can be maintained at safe operating temperatures while still providing effective warming through direct thermal contact with the patient.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution provides a safe, efficient, and cleanable heating solution for surgical patients, reducing the risk of burns and microbial contamination while maintaining effective temperature control and ease of cleaning.

Implementation Method 1

flexible electric heating blanket... conductive fabric heating element

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

shell covers the heating blanket and includes two sheets of flexible material welded together

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11388782B2Heating blanket

Publication Date: 2022.07.12 AUGUSTINE TEMPERATURE MANAGEMENT LLC

AI summary

An electric blanket including a flexible sheet-like heating element, a shell comprising two flexible sheets covering the heating element, one or more welds coupling the sheet of the shell about the edges to hermetically seal the heating element there between; and a flexible insulating layer extending over the heating element and covered by the shell providing at least one of thermal insulation and electrical insulation, wherein the heating element is held in position between the two sheets of the shell without using connectors that pierce the two sheets.