KR102506802B1 - Method of manufacturing splint and splint manufactured thereby - Google Patents

Abstract

The present invention relates to a novel splint manufacturing method and a splint manufactured by the manufacturing method, and more particularly, to a splint that can be mass-produced and standardized by including a step of cutting a splint manufacturing fabric using a laser and a bias treatment step. It relates to a manufacturing method and a splint manufactured using this manufacturing method.

Description

Manufacturing method of novel splint and splint manufactured by this manufacturing method {Method of manufacturing splint and splint manufactured thereby}

The present invention relates to a novel splint manufacturing method and a splint manufactured by the manufacturing method, and more particularly, to a splint that can be mass-produced and standardized, including a step of cutting a splint manufacturing fabric using a laser and a bias treatment step. It relates to a manufacturing method and a splint manufactured using this manufacturing method.

When an arm or leg is broken or sprained, non-surgical treatment is performed to immobilize the injured fractured part with an orthopedic splint. As a fixing method that functions as such an orthopedic splint, a method of fixing by wrapping a bandage coated with gypsum on the affected area is widely used (Patent Document 1).

However, in the surgical method using such a gypsum, contraction occurs in the process of hardening the gypsum, so that the affected area cannot be effectively supported and it takes a considerable amount of time to apply a gypsum bandage to the affected area.

In addition, since it is not breathable, when used for a long time, there is a problem of sweating and causing itching. Moreover, the treatment method using gypsum has problems such as damaging the skin during cutting because a separate cutter must be used to remove it when the treatment of the affected area is completed in a state in which curing is completed after the procedure.

In order to solve the above problems of the gypsum fixing method, a splint using a mesh-type resin fabric having excellent air permeability has been manufactured and used (Patent Invention 2).

In the conventional splint manufacturing method, a splint molded body is manufactured by attaching a multi-layered reinforcing material of a resin fabric cut to a splint molded body base cut to a predetermined size from a mesh-shaped resin fabric and molding it into the shape of an affected part.

Conventionally, cutting of the resin fabric is performed using a manual or automatic mechanical means.

However, since the resin fabric in the form of a mesh having excellent air permeability is manufactured by impregnating the fabric of the mesh with a resin, the shape is not constant.

Therefore, when the resin fabric is cut by automatic mechanical means, there is a disadvantage in that the surface of the impregnated resin is detached, and when it is cut manually, it takes a lot of time and effort, and a large amount of fabric in various shapes, There is a disadvantage that it is difficult to cut in the form of a size and a certain standard. On the other hand, some prior literature describes cutting using a laser for splint production, but does not disclose a specific method (Patent Document 3). In particular, in the case of including thermoplastic resin and fiber, a cutting method using a laser is not known.

In addition, in the case of a splint molded using a resin fabric, since the outer surface of the splint is exposed as it is, there is a disadvantage in that a wound may occur due to contact with the skin or affected area when using the splint (Patent Document 3). . In particular, in the manufacturing method of the splint of Patent Document 3, the main molding part and the sub molding part are manufactured separately, and the manufacturing process and the splint are used to treat the affected area, and the process is complicated.

On the other hand, the current splint uses one type of splint regardless of the fracture site and degree. However, during non-surgical treatment of fixing a fracture site using a splint, splints of various shapes, strengths, and sizes are required depending on the injured fracture site, and furthermore, a standardized splint is required.

Therefore, there is an urgent need for a new splint manufacturing method capable of producing a standardized splint that is simple, safe, economical, and excellent in moldability of the splint when using the splint in the manufacture of the splint.

KR No. 2010-0015972 (published on February 12, 2010) KR No. 10-1768490 (2017.08.30. Notice) KR No. 10-2070654 (2020.01.30. Notice)

The present invention is to solve the above-mentioned problems of the prior art, and relates to a novel splint manufacturing method that can be mass-produced and standardized, including a step using a laser and a bias processing step, and a splint manufactured using the manufacturing method. will be.

The manufacturing method of the splint according to the present invention for achieving this object is

(a) manufacturing a splint molded body base by laser cutting designed resin fabrics of various sizes;

(b) processing the contour surface of the splint molded body base with a bias;

(c) softening the bias-processed splint molding base ('splint molding material');

(d) molding the softened splint molded material into the shape of each splint according to the affected part;

It is characterized in that step (b) is performed after step (a), and then steps (c) and (d) are performed.

In the manufacturing method of the splint of the present invention, the steps (c) and (d) may be performed in separate processes or in one process.

In addition, the manufacturing method of the splint of the present invention,

(a-1) attaching a reinforcing material; and (e) attaching the Velcro tape and the cushion pad. Step (a-1) may be performed after step (a), and step (e) may be performed after step (d).

In addition, the resin fabric of the method for manufacturing a splint according to the present invention is characterized in that it contains a thermoplastic resin.

In addition, in the manufacturing method of the splint of the present invention, the laser in step (a) is characterized in that a CO2 laser is used.

In addition, in the manufacturing method of the splint of the present invention, the bias treatment in step (b), the softening in step (c), and the molding in step (d) may be performed manually or automatically.

In addition, the splint according to the present invention is manufactured by the above method of manufacturing the splint, and includes only one molding part without an auxiliary molding part, and the one molding part is single-layered, partially or entirely laminated. do.

The splint manufacturing method according to the present invention has the advantage of being able to mass-produce splints of a certain standard, including using a laser in step (a) and biasing before forming the splint in step (b).

In addition, it is possible to manufacture a splint suitable for the condition of the affected area through standard production of splints of various shapes, strengths, and sizes suitable for the affected area according to the injured fracture site, which has the advantage of being helpful in treating the affected area. It is possible to prevent pressure damage such as skin pain or skin piercing due to the contoured surface of the molded splint by bias treatment before molding. In addition, since the outside of the splint molded body base is fixed by bias treatment before molding, a splint having an accurate molded shape can be manufactured without the shape of the splint being distorted after molding, thereby making the standard form of the splint product constant There are advantages.

On the other hand, in the prior art of bias treatment after molding, since the shape of the product after molding is not accurate, it is necessary to go through a step of softening the product once again after the bias treatment, and then a step of accurately correcting the standard shape of the product. Therefore, the bias treatment before molding in the step (b) of the present invention is not only economically beneficial in the process due to the shortening of the manufacturing step compared to the prior art, but also standardization of the splint product produced by producing splint products of accurate specifications, so that even during the procedure, the affected area It has the advantage of being able to carry out precise procedures.

Furthermore, in the prior art, due to the characteristics of a thermoplastic resin having breathable holes, which is a material of a splint, the bias could not be mechanically processed, and the bias was softened in hot water or hot air from a hot gun and then manually processed. Standardization of the product production process and mass production with a fast process by processing it in an appropriate way, as well as showing economic effects in the process.

In addition, since the splint manufactured by the splint manufacturing method according to the present invention contains a thermoplastic resin, a doctor or related person can directly adhere to the affected area through a softening process at the site or hospital, and during such a procedure, the manufacturing method of the present invention The splint made of is standardized in various shapes, strengths, and sizes suitable for the affected area according to the injured fracture site, so it has the advantage of being simple to operate without much effort.

1 is a photograph showing a splint manufactured according to a first embodiment of the splint according to the present invention (methods of manufacturing steps (a), (a-1), (b), (c) and (d)).
Figure 2 shows a splint manufactured by a second embodiment of the splint according to the present invention (methods of manufacturing steps (a), (a-1), (b), (c), (d) and (e)) It is a picture.
3 is a photograph of a laser device used in the method of manufacturing a splint according to the present invention.
Figure 4a is the laser specific conditions of the present invention (30 to 70% power and 20 to 70 mm / s of the total output This is a picture showing the carbonization state of the splint molded body base cut at the cutting speed).
Figure 4b is the laser specific conditions of the present invention (30 to 70% of the total output power and 20 to 70 mm / s of This is a picture showing the cutting (cutting) state of the splint molded body base cut at the cutting speed).
Figure 4c is a photograph showing the carbonization state of the splint molded article base cut under conditions out of the laser-specific conditions of the present invention (power exceeding 70% of total output and cutting speed exceeding 70 mm/s).
Figure 4d is a photograph showing the cutting (cutting) state of the splint molded article base cut under the conditions outside the laser-specific conditions of the present invention (power exceeding 70% of total output and cutting speed exceeding 70 mm/s).
Figure 4e is a photograph showing the carbonization state of the splint molded article base cut under another condition (power less than 30% of total output and cutting speed less than 20 mm / s) out of the laser-specific conditions of the present invention.
Figure 4f is a photograph showing the cutting (cutting) state of the splint molded body base cut under another condition (power less than 30% of total output and cutting speed less than 20 mm / s) out of the laser-specific conditions of the present invention.
Figure 5a is a photograph showing a splint molded body base ('splint molded material') in which the bias treatment in step (b) of the splint manufacturing method according to the present invention is automatically mechanically processed within the needle range of the present invention.
5B is a photograph showing the bias treatment state when the mechanical treatment for bias treatment in step (b) of the method for manufacturing a splint according to the present invention is out of the needle range of the present invention (needle size 90/14).
Figure 6a is a photograph showing the shape of the molded splint after the bias treatment of step (b) in the manufacturing method of the splint according to the present invention.
6B is a photograph showing the shape of a temporary splint molded without going through the bias treatment step of step (b).
6C is a photograph showing the shape of a splint manufactured by biasing the false splint of FIG. 6B.
7 is a block diagram showing a method for manufacturing a splint according to the present invention.

Hereinafter, the manufacturing method of the splint of the present invention and the splint manufactured by the manufacturing method will be described in detail with reference to the accompanying drawings.

The drawings introduced below are provided as examples to sufficiently convey the spirit of the present invention to those skilled in the art. Accordingly, the present invention may be embodied in other forms without being limited to the drawings presented below. Also, like reference numerals denote like elements throughout the specification.

In terms of terms used in the following description, unless otherwise defined, all terms (including technical and scientific terms) used in this specification will be used in a meaning that can be commonly understood by those of ordinary skill in the art to which the present invention belongs. The singular form also includes the plural form unless specifically defined in the sentence.

In the drawings and descriptions of the present specification, the splint includes a splint that can be used not only for orthopedic treatment but also for cosmetic procedures. In addition, in the following description and accompanying drawings, descriptions of known functions and configurations that may unnecessarily obscure the subject matter of the present invention may be omitted.

The present invention is to provide a method for manufacturing a novel splint, the method for manufacturing the splint comprising:

(a) manufacturing a splint molded body base by laser cutting designed resin fabrics of various sizes;

(b) processing the contour surface of the splint molded body base with a bias;

(c) softening the bias-processed splint molding base ('splint molding material');

(d) molding the softened splint molded material into the shape of each splint according to the affected part; characterized in that it comprises a.

In addition, the manufacturing method of the splint of the present invention includes the steps of (a-1) attaching a reinforcing material; and (e) attaching the Velcro tape and the cushion pad, and the step (a-1) is performed after the step (a) and before the step (b).

The method for manufacturing a splint of the present invention is characterized in that step (b) is performed after step (a) and/or step (a-1), followed by steps (c) and (d).

In addition, steps (c) and (d) may be performed as separate steps or simultaneously.

Specifically, the step (a) is a step of manufacturing a splint molded body base by laser cutting designed resin fabrics of various sizes, and the splint molded body base may be a single layer or, if necessary, may be made of multiple layers.

The resin fabric of step (a) includes a thermoplastic resin, and the thermoplastic resin may preferably be a polyester-based resin, a polyurethane-based resin, or a mixture thereof.

In addition, the resin fabric of step (a) may include fibers, and in the case of including fibers, the fibers may be coated with a thermoplastic resin, or the fibers may be impregnated with the thermoplastic resin. The fiber may be a natural fiber such as cotton thread or wool, a yarn, or a synthetic fiber such as nylon or polyester.

Specifically, the resin fabric may be a resin fabric in which woven fibers are coated with a thermoplastic resin, or the woven fibers are impregnated with a thermoplastic resin and have a network structure in which ventilation windows are repeatedly formed, and the size of the ventilation windows is required. It may be determined according to, and preferably has a size of 3 to 8 mm 2 .

The resin fabric may have a softening point of 40 to 75°C.

The laser for cutting the resin fabric in step (a) is a CO2 laser, and has an output of 150W. When cutting the resin fabric using the CO2 laser, the power is 30 to 70% of the total output, and the cutting speed of the resin fabric is 20 to 70 mm/s. Preferably, the power is 30 to 45% of the total output, and the cutting speed of the resin fabric is 20 to 40 mm/s. More preferably, the power is 35 to 38% of the total output, and the cutting speed is 25 to 35 mm/s. If it is out of the above range, difficulty may occur in forming a splint molded article base having excellent marketability due to poor cutting (cutting) of the resin fabric or an unclean cut surface due to carbonization of the resin fabric.

The results of laser cutting in step (a) are shown in Figs. 4a to 4f. 4a and 4b are photographs showing the degree of carbonization and the degree of cutting (cutting degree) of the cut surface at the power of 35% to 38% of the output, and the cutting speed of 25 to 35 mm / s, which are the conditions of the laser cutting of the present invention, respectively. It can be seen that it hardly occurs and the degree of cutting is excellent.

On the other hand, the results of laser cutting at a power of more than 70% and a cutting speed of more than 70 mm / s outside the laser cutting conditions of the present invention are shown in FIGS. The degree (degree of cutting) appears to be poor.

In addition, Figures 4e and 4f are photographs showing the results of laser cutting at a power of less than 30% and a cutting speed of less than 20 mm / s outside the laser cutting conditions of the present invention, the degree of carbonization in the cut surface is severe, and the cutting is almost It shows that it doesn't work.

The carbonization causes the finished splint to look unclean in appearance, which may cause a problem in the marketability of the manufactured splint, and if the cutting is poor, it not only causes a problem in the manufacturing speed in the process, but also in the next step (b ) in the bias processing step, the cut surface is not uniform, which may cause a problem in the bias processing.

The step of attaching the reinforcing member (a-1) may be configured as necessary after step (a), and may be performed before the bias processing step of step (b). The attachment of the reinforcing material in step (a-1) is to attach the splint molded body base of the resin fabric cut by the laser in step (a) (see FIG. 2).

The reinforcing material may be the same material as the resin fabric in step (a), or may be a different material if necessary, and another material may be a material containing a thermoplastic resin.

The reinforcing material may be cut using a laser.

In the case of attaching the reinforcing material in step (a-1), if the reinforcing material is the same material as the resin fabric in step (a), the splint molded body base and the reinforcing material are softened, respectively, and then the reinforcing material is attached to the splint molded body base without a separate adhesive. Attached to, the softening method may be immersed in hot water of 40 to 85 ° C., or high temperature air may be used. The attachment position may be determined according to need, and for example, in the case of a heavy load, the heel part may be attached to the heel part when strength is required.

In addition, when the reinforcing material is another material containing a thermoplastic resin, the splint molded body base is softened using hot water or high-temperature air at 40 to 85 ° C, and other materials containing a thermoplastic resin are softened at the above temperature, Alternatively, the reinforcing material is attached to the splint molded body base using an adhesive. The other material may have a softening point of 100°C or less.

When attaching the softened splint molded article base and the reinforcing member, a certain pressure may be applied at the time of attachment in order to increase attachment strength.

The reinforcing material is for reinforcing the strength of the splint, and for convenience and appearance after wearing the splint. In particular, strengthening the strength of the splint is to minimize movement of the affected area for quick recovery after a fracture, and to maintain the affected area at a constant strength or to reinforce the strength of the splint at a portion subjected to a load due to movement. The strengthening of the strength of the splint greatly improves the strength of the splint without significantly increasing the overall load of the splint, minimizing the movement of the affected area, and by enduring the pressure from the outside until complete recovery after wearing the splint, the splint is well attached to the affected area. It also shows the effect of ease of use. In addition, although the strength of the splint is increased by the attachment of the reinforcing material, there is an effect of making the splint not stand out greatly in appearance even when the splint is worn.

In the bias processing step of (b), the contour surface of the splint molded body base cut with the laser or the splint molded body base to which the reinforcing material manufactured in step (a-1) is attached is processed with bias.

The bias of step (b) may be made of a thermoplastic material, and in particular, the via may be made of the same material as the resin fabric of step (a). A preferred bias material may be a non-woven fabric.

In addition, the bias processing of the contour surface in the step (b) may be performed by a manual method or an automatic method.

The manual method is performed by softening the splint molded body base and the bias material, respectively, and then attaching the bias material to the contour surface of the splint molded body base. At this time, the softening temperature is appropriately 40 to 85 ° C., and the softening method may be immersed in a heat bath or high-temperature air using a hot gun or a heat heater.

The automatic method may use a mechanical method, and in particular, is a method of biasing the contour surface of the splint molded article base using a sewing machine. This automatic method omits the softening step of the splint molded body base and the bias material, so the process is convenient and thus has the advantage of economic benefits in the process and also has the advantage of enabling mass production.

In bias treatment by the automatic method of an embodiment of the present invention, the sewing machine uses a needle thickness of 100/16 to 300/29, preferably 120/19 to 300/29, and more preferably 125/20 to I use 200/25. If the needle thickness is out of range, there is a disadvantage in that the stitching is not performed or the bias is not well attached due to poor fixation by the stitching (see FIGS. 5A and 5B).

Step (a) is performed by processing the contour surface of the splint molded body base by laser cutting in step (a) of step (b) or the splint molded body base to which the reinforcing material is attached manufactured by step (a-1) is treated with a bias. There is an effect of fixing the contour of the splint molded body base or the splint molded body base to which the reinforcing material in step (a-1) is attached.

The splint molded body base in step (a) or (a-1), the shape of which is fixed by the bias in step (b), is formed during splint molding in steps (c) and (d) after step (b). , Unlike the splint molded body base in which the splint is not biased, it has the effect of being well molded in the shape of the mold in the shape of the affected body part, and such excellent formability can enable standardization and mass production of the splint.

Effects of the bias processing in step (b) are shown in FIGS. 6A to 6C.

6A and 6C are pictures of a splint molded and manufactured after bias treatment in step (b) of the present invention, and a photograph of a splint manufactured by a bias process after molding in the prior art, respectively.

6A is a photograph showing the molded splint after bias treatment in step (b) of the present invention, and the shape of the splint is excellent.

However, in the prior art that does not go through step (b) of the present invention, in order to manufacture the splint of FIG. 6c, the splint is manufactured by molding the temporary splint as shown in FIG. 6b and then applying a bias to the temporary splint. The splint of FIG. 6c manufactured using the above technique has a different shape compared to the splint of FIG. 6a according to the present invention.

As described above, according to the method for manufacturing a splint including step (b) of the present invention, there is an advantage in that a splint having a standard shape and standard can be produced.

A splint having a standardized shape and standard is excellent in ease of use.

The step (c) is a step of softening the biased splint molding base ('splint molding material'), and the softening method may include immersion in a heat bath, high-temperature air, or heating. The softening temperature is 40 to 85°C. A preferred softening method is immersion in a hot water bath, using a hot gun, or a heat heater.

In addition, the softening method consisting of immersion in the hot water bath may be characterized by repeatedly immersing in hot water of 40 to 85 ° C. several times, and cooling at room temperature for about 0.5 to 3 minutes after immersion. The number of times of immersion may be determined according to the degree of softening, and may be preferably 3 to 7 times.

The softening in step (c) may be performed manually or automatically.

(d) The step of molding the softened splint molding material into the shape of each splint is to manufacture the splint by molding the softened splint molding material into the shape of the body part of the affected part where the fracture occurred so that it can be hardened (Fig. 1).

The softening in step (c) and the shaping of the splint in step (d) may be distinguished as separate steps, or shaping may be performed after softening in one step.

The manufacturing method of the novel splint of the present invention may further include (e) attaching the Velcro tape and the cushion pad after the step (d) (see FIG. 2).

The Velcro tape serves to fix the splint on the affected part, and the Velcro tape is attached to the splint by attaching a ring-shaped fixing ring to the outer surface of the splint, or attached to a necessary portion using an adhesive.

In addition, the cushion pad is for preventing pressure applied to the affected area by the splint when the splint is applied to the affected area, and is attached to the affected area of the splint using an adhesive.

Materials widely known in the art may be used for the Velcro tape and the cushion pad.

The present invention is also characterized by providing a splint manufactured by the manufacturing method of the splint of the present invention as described above.

As described above, the method for manufacturing a novel splint according to the present invention has the advantage of being able to operate a splint with a structure that is suitable and fits the affected area by standardizing the shape, size, strength, etc. of the splint according to the affected area, and mass production is possible. This has the advantage of lowering the unit price of the splint and reducing the burden on the patient.

Claims (14)

(a) manufacturing a splint molded body base by cutting thermoplastic resin fabrics of various sizes with a laser;
(b) processing the contour surface of the splint molded body base with a bias;
(c) softening the bias-processed splint molding base ('splint molding material');
(d) molding the softened splint molded material into the shape of each splint according to the affected part; step (b) is performed after step (a), and steps (c) and (d) are then performed Characterized in that, the manufacturing method of the splint. The method of claim 1,
The laser in step (a) is a CO2 laser with an output of 150 W, and the cutting of the resin fabric is performed at a power of 30 to 70% of the total output of the CO2 laser and a cutting speed of 20 to 70 mm / s, manufacturing a splint, characterized in that method. The method of claim 2,
The cutting of the resin fabric is performed at a power of 30 to 45% of the total output of the CO2 laser and a cutting speed of 20 to 40 mm / s, a method for manufacturing a splint. The method of claim 3,
The cutting of the resin fabric is performed at a power of 35 to 38% of the total output of the CO2 laser and a cutting speed of 25 to 35 mm / s, a method for manufacturing a splint. The method of claim 1,
The bias processing in step (b) is characterized in that it is performed by a manual method or an automatic method,
The manual method includes the step of softening the splint molded body base and the bias at 40 to 85 ° C, respectively, and then attaching the bias to the contour surface of the splint molded body base,
The method of manufacturing a splint, characterized in that the automatic method consists of one step of directly attaching a bias to the splint molded article base without a softening step using a mechanical method. The method of claim 5,
The mechanical method is to use a sewing machine, characterized in that the needle size of the sewing machine is 100/16 to 300/29, a method for producing a splint. The method of claim 5,
The method of manufacturing a splint, characterized in that the softening of the manual method is performed using hot water, a hot gun, or a heat warmer. The method of claim 1,
The method of manufacturing a splint, characterized in that the softening temperature in step (c) is 40 to 85 ° C. The method of claim 1,
The method of manufacturing a splint, characterized in that the softening in step (c) is performed using hot water, a hot gun, or a heat warmer. According to any one of claims 1 to 9,
(a-1) attaching a reinforcing material; and (e) attaching the Velcro tape and the cushion pad, wherein step (a-1) is performed after step (a) and before step (b). . The method of claim 10,
The reinforcing material in the step (a-1) may be the same as the splint molded body base or may be another material containing a thermoplastic resin, and the other material has a softening point of 100° C. or less.
When the reinforcing material is the same material, the splint molded body base and the reinforcing material are softened, and then the reinforcing material is attached to the splint molded body base without a separate adhesive. The softening method is immersion in hot water at 40 to 85 ° C. using hot air
When the reinforcing material is another material containing a thermoplastic resin, the splint molded body base is softened using hot water or high-temperature air at 40 to 85° C., and other materials containing a thermoplastic resin are softened at the above softening temperature. A method for manufacturing a splint, characterized in that the reinforcing materials are attached to each other or to the splint molded body base using an adhesive. Splint manufactured using the manufacturing method of any one of claims 1 to 9 Splint manufactured using the manufacturing method of claim 10 Splint manufactured using the manufacturing method of claim 11

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