Patent Application
20150369325
The invention relates to an element with variable stiffness controlled through negative pressure, such as suction or vacuum. The present invention is applicable:
to certain medical devices (such as casts, functional orthoses, insoles, and emergency medical devices such as splints for limbs and full body first aiders),
to sporting goods (such as skates, ski boots, surfboards and protective equipment in sports such as helmets or knee and chest guards),
to safety elements that rigidify in case of a collision or accident,
to constructive elements for example to be used to make reconfigurable camping furniture or toys,
to mold-elements for production of composites,
to packaging elements, or
to safety elements that rigidify in case of a collision or accident, for example, in the automotive field.
It is known to use negative pressure such as suction or vacuum to provide a way to convert an element from a flexible state, in which the element is easily formed and can be adapted to conform a specific desired shape (such as a part of the human body), to a rigid state, in which the element is rigid and provides support, protection and/or stabilization, and vice versa. The basic structure of devices employing negative pressure usually comprises inner fillers which are commonly movable particles and a flexible, air-impermeable thin outer cover. The structure normally enables the device to be easily and readily fitted around the body and affected limbs. When the device becomes the desired shape in the desired position, it is subjected to negative pressure and then atmospheric pressure compresses the flexible outer cover and applies substantial pressure to the entire mass of particles. The frictional force between the particles and the cover resist movement relative to each other, thereby providing rigidity. Usually a valve is included for sealing the cover when evacuated to maintain rigidity of the device. The soft state from the rigid state is usually obtained by opening the valve and whiff.
Several patents about orthopedic devices employing negative pressure have been published. Patent document US 2005/0137513 discloses a structure to maintain a homogeneous thickness for devices for supporting and stabilizing an injured person or body parts. The device has an inner region enveloped by two flexible films and the inner region is divided into two insertion bodies which are respectively formed with two air-permeable, flexible material strips. Each insertion body is divided into chambers containing loose particles, by way of intersecting seams formed between the material strips. The seams on both insertion bodies are staggered in relation to each other in both directions in such a way that the particles combine to form a substantially homogeneously thick particle layer. However, such a structure made of granules or particles has the problem of being too thick, which leads to practical limitations such as transporting size, and a high volume leading to problems such as a long evacuation time to reach the desired negative pressure level.
In order to solve the problem of undesired thickness and volume, the body fitting element a with controlled fitness disclosed in patent document WO 2011/07985 is made of a gas tight envelope enclosing a plurality of layers and having a valve adapted to evacuate the interior of the envelope. Each layer is made of a core made of a material with a high Young modulus and flexibility coated on both sides with a cover layer made of a material with a high friction coefficient. However, such a body fitting element presents the following problems:
Once vacuum has been applied and the body fitting element is in its rigid state, when the valve is opened to go to the flexible state, the fact is that the layers may keep stuck one to the other due to their tackiness, and the flexible state is thus not recovered properly.
In the rigid state, when under a bending stress, the layers may delaminate (disconnect the coating from the core).
The body fitting element disclosed in WO 2011/07985 included some strips made of a material with a low friction coefficient, in order to properly recover the flexible state under atmospheric pressure. However, these strips reduce the effective friction surfaces, which consequently reduces the stiffness of the element in rigid state and thus affects its proper functioning.
In sum, an element with controllable stiffness is needed, which solves in an efficient way both the problems of tackiness and delamination, in the scenario described above.
The present invention refers to an element with variable stiffness controlled by negative pressure.
An element is provided with variable stiffness controllable by negative pressure which overcomes the tackiness and delamination problems of the existing elements with controllable stiffness. In order to do so, the element with variable stiffness controllable by negative pressure of the present invention is fully reversible between the flexible and rigid states, at the same time maintaining or even improving the stiffness ratio between the rigid and flexible state compared with the stiffness ratio of current solutions.
The element with variable stiffness controlled by negative pressure of the present invention comprises:
a gas-tight envelope;
a plurality of flexible layers in the envelope, each layer having a first surface and a second surface; and,
a valve adapted to evacuate the interior of the envelope.
According to a first aspect of the invention the first and second surfaces of two adjacent layers:
have a friction coefficient between each other which is higher than 0.5; and
have adhesion properties, such that a normal force per unit area of no more than 0.07 N/mm2 is required to separate them and/or the energy per unit area required to separate them in normal direction being below 6.7 J/m2.
Thus, the element of the present invention has a laminar structure comprising several layers and has the following properties:
high friction coefficient between layers due to the selection of materials used and the fact that the whole surface of the layers support friction; and,
low adhesion between layers, especially when there is no normal force.
This way the first and second surfaces are slidable relative to each other under atmospheric pressure.
A further advantage of the present invention is that the layers can be made thinner than the layers of prior-art elements (which included coated core layers), due to the fact that the layers can be made of a single material or composite with the necessary properties of high friction coefficient and low adhesion properties, thereby eliminating the need for both coating layer and core, and the corresponding adhesive layer between them.
With this specific element configuration of the invention the stiffness ratio of the element between its flexible and rigid states is improved:
firstly, because the layers are not stuck to each other at atmospheric pressure, which makes the element more flexible and easier to shape in its softer state; and
secondly, since there is no need for strips of low friction or sewing, the friction surface is increased which makes the element stiffer in its rigid state.
Depending on the applications of the element, the layers can be made of a single material, or they can be made of a plurality of fibers embedded in a matrix. In both cases the layers can be made of a continuous or homogeneous sheet, or the layer can be made of a woven structure of tapes or ribbons.
Where the layers are made of a matrix reinforced with fibers, the fibers can be unidirectional, bidirectional or multidirectional. Only the composites having unidirectional fibers are suitable for the woven structure with tapes.
The fibers are preferably selected from fiber glass, carbon, aramid or polyester fibers. And the matrix is preferably made of a thermostable polymer or a thermoplastic polymer.
According to another preferred embodiment, the layers can comprise a core layer coated by at least one coating on one side of the core. Preferably the core is coated by respective first and second coatings, one coating on each side of the core.
Such coatings are preferably made of a thermoplastic polyurethane elastomer.
The adhesion properties of the layers are preferably measured using an adapted version of a standardized method, such as the ASTM D2979-01, “Standard test method for pressure-sensitive tack of adhesives using an inverted probe machine”. Preferably the adhesion properties are measured using a probe-tack test with a pre-load equivalent to the atmospheric pressure and a waiting pre-load time of 100 s.
The friction coefficient is preferably measured using a standardized procedure such as the ASTM D 1894 “Standard test method for static and kinetic coefficients of friction of plastic film and sheeting”.
In the case of layers being made of woven tapes, the adhesion properties can be measured using the adapted probe-tack test on a specific number of tapes placed adjacent to each other over a flat surface, such that the resulting width is higher than the minimum value set by the standard.
The adhesion properties of the layers are measured on layers as they are in its conditions of use; that is, although the standard indicates that the layers should be cleaned before any measuring is carried out, for measuring the adhesion properties of the layers of the element in the present invention the layers need not be previously cleaned; their adhesion properties should be measured in the same conditions as when they are in use inside the element.
Additional advantages and features of the invention will become apparent from the detailed description that follows and will be particularly pointed out in the appended claims.
To complete the description and in order to provide for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate an embodiment of the invention, which should not be interpreted as restricting the scope of the invention, but just as an example of how the invention can be carried out. The drawings comprise the following figures:
The following description is not to be taken in a limiting sense but is given solely for the purpose of describing the broad principles of the invention. Next embodiments of the invention will be described by way of example, with reference to the above-mentioned drawings showing elements and results according to the invention.
In a known manner, when atmospheric pressure is inside the envelope 10, the layers 30 are uncompressed. When vacuum is applied, the flexible layers 30 are compressed together increasing the friction between them, which in turn increases the stiffness of the element 1 as a whole. This way the element 1 has variable state possibilities, from a soft, flexible state at atmospheric pressure to a rigid state when depressurized.
The novelty of the present element 1 resides in the specific structure and material of the layers 30, as shown in
In order that the element 1 works properly and its flexible or soft state is adequately recovered once vacuum has been applied and afterwards released, it is important that the first and second surfaces 31, 32 of the layers are made of such materials, thickness and surface finish that result in both a high friction coefficient and low adhesion connection.
The layers are such that the friction coefficient between the first surface 31 and the second surface 32 of two adjacent layers 30 is higher than that of materials normally used for lubrication. The friction coefficient between the surfaces is above 0.6. More preferably, the friction coefficient is above 1.
In order to measure the friction coefficient a standardized procedure can be used, such as the ASTM D 1894 “Standard test method for static and kinetic coefficients of friction of plastic film and sheeting”. An essential requisite of the layers is that they have low adhesion properties. By low adhesion it is meant that the tangential adhesion force between the first and second surfaces 31, 32 of two adjacent layers 30 is such that the layers 30 slide relative to each other when there is no normal force. In fact, the first and second surfaces of the layers have low adhesion properties such that a normal force per unit area of below 0.07 N/mm2 is required to separate them (that is, a compressive normal force of −0.07 N/mm2), and/or the energy per unit area required to separate them in normal direction being below 6.7 J/m2.
This is an important feature to prevent the different layers to remain stuck to each other once the vacuum is no longer applied and the element 1 recovers its flexible state.
It should be considered that the friction and tackiness properties of the layers are not only influenced by the material of the layer, but also by the thickness and the surface finish (roughness Ra) of the layer. This is why in order to characterize the interface between the first and second surfaces 31, 32 of two adjacent layers 30 the friction and tackiness tests are made on two flexible layers 30 to take into account the effect of the manufacturing processes.
The adhesion properties have been measured by means of an adapted probe-tack test with a pre-load equivalent to the atmospheric pressure and a waiting pre-load time of 100s, which is the maximum timescale mentioned in the norm for adhesive properties to settle.
A standardized method to measure adhesion of adhesives is described by ASTM D2979-01, “Standard test method for pressure-sensitive tack of adhesives using an inverted probe machine”. In the present case an adapted version of this method has been used. The standardized method had to be modified since adhesion between layers which are not adhesives is being measured; these layers have a lower adhesion force, and where the adhesion depends on the material, thickness and roughness of the layers. The layers can be cleaned with alcohol (or any other means) prior to the measuring, as indicated in the standard. But it is possible to take the measurements without previously cleaning the surface of the layers, in order to not alter the adhesion properties of the layers on their conditions of use.
What is important is that the standardized method is repeated several times, so as to have a statistically significant number of measurements, such that it is possible to disregard outlier values.
The measuring method is schematically shown in
More specifically:
The specific adaptations to the standardized test are:
A circular contact surface of 50 mm is used, instead of the 5 mm probe of the standard, because of lower adhesion forces. In the case of an embodiment comprising tapes, a number of tapes should be lined up next to each other, so that lined up together they cover the circular surfaces of 50 mm.
A normal upright probe machine is used instead of an inverted probe machine, because of lower adhesive forces.
The test of adhesion is carried out between the actual layers of the element, instead of carrying out the test between a stainless steel probe and the adhesive.
The constant speed approaching movement is stopped when the value Fmax is reached; at this point the probe machine is programmed to keep the static load constant at Fmax. The value of Fmax used is 200 N, which corresponds to a compressive load in the order of magnitude of the atmospheric pressure on the surface.
The probe is lifted vertically upwards from a resting surface during steps c-f.
The static load is maintained for 100 s (instead of 1 s).
Real layers are used in the test, instead of the specified adhesive surface layer thickness specified in the norm.
Values are averaged over at least five measurements.
The adhesion is characterized by:
by Fadh/Asurface, where Fadh is the maximum force measured while disconnecting the surfaces and Asurface is the area of the contact surface, and
by ωadh/Asurface, where ωadh is the energy required to disconnect the two layers.
The following Table 1 shows examples of layers, the adhesion properties of which have been measured with the adapted probe-tack test just explained.
A preferred embodiment of the element 1 of the invention example I, having the flexible layers 30 of
For certain applications it is necessary that the element of the invention has a certain degree of stiffness. In order to obtain such stiffness, the layers of the element can be improved as shown in any of
The core 40 is essentially a continuous sheet of a flexible material having a high Young's modulus. Having a high Young's modulus means that the Young's modulus of the core is higher than the Young's modulus of the materials used because of their elasticity (such as rubbers). Besides, the Young's modulus of the material constituting the core 40 is higher than Young's modulus of the material of the coatings 41, 42. The material forming the core 40 preferably has a Young's modulus above 0.2 GPa, such as LDPE, which provides the element with stiffness valid for certain applications.
Preferably the Young's modulus of the core 40 material is higher than 0.8 GPa.
The core can be made of any of the following materials:
Thermoplastics such as ABS, PEEK, PP, PEHD or PVC.
Metals such as aluminum, brass, or iron.
Wood, paper.
It is possible that the first and second coatings 41, 42 on each side of the core 40 are made of the same material, including specific layer thickness and surface finish, resulting in high friction coefficient and low adhesion properties, as is the case of the layer shown in
Additionally, in the embodiment of the layer 30a shown in
Similarly, in the embodiment of the layer 30b of
Suitable materials for the coatings are: some thermoplastic polyurethanes, Acronal/Styrofan resin (40% of Acronal® 12 DE with 60% of Styrofan® D422, from BASF), polyurea resin, silicone, rubber, silicone rubber, latex.
To further improve the stiffness properties of the element 1 for those applications that may require it (such as construction elements), the layers can comprise a matrix reinforced with fibers.
As shown in
The matrix's material in the case of
A preferred embodiment of the element 1 of the invention, example II, having the flexible layers 30c or 30d of
The layer 30e in
The fibers in the layers of
The fibers 301 in the embodiments shown
In the following examples the friction coefficient between surfaces made of a PUR-resin (Polyol) with a PUR-hardener (Isocyanate) has been determined with a sled of metal block 60×54 mm, weighing 268 g, and a pre-load of 0.2 N. The rest of the conditions used during testing of the materials are those described in the standard ASTM 1894:
*Polyurea (RAKU-TOOL® PC-3411 resin with RAKU-TOOL® PH-3911 Isocyanate from RAMPF®), reinforced with bidirectional carbon fiber fabric (200 g/m2). Its friction coefficient was measured to be 2.25.
*Polyurea (RAKU-TOOL® PC-3411 resin with RAKU-TOOL® PH-3911 Isocyanate from RAMPF®), reinforced with bidirectional glass fiber fabric (204 g/m2). Its friction coefficient was measured to be 2.20.
These two examples are used to measure the friction coefficient of the polyureas, in the layer 30c where the surfaces are made with the same material as the matrix 302 reinforced with fibers 301 (
When the element 1 is used as an orthopedic device, it is capable to adapt to the individual shape of the limb of the patient. In its flexible state the element 1 is adapted to the shape of the limb, and when vacuum is applied the element 1 locks to its rigid state to provide support and stabilization. For this purpose, it is important to have a high stiffness ratio between the flexible and rigid states in addition to each layer preferably being made of a material with a high Young's modulus. In an ideal case, the layers 30, when in the rigid state, are completely stuck to each other through the applied negative pressure, the stiffness of the element is n2 times higher than in the flexible state under atmospheric condition, n being the number of layers in the element. In the real case this stiffness-increase factor of n2 is approached, depending on the actual coefficient of friction that still may allow some sliding between the layers. For example, an element having a thickness of 2.4 mm made of 6 layers of 0.4 mm each has a stiffness ratio between the rigid and flexible states of 36 (=6̂2). The stiffness ratio to be achieved by the element depends on the type of application. For instance, a ratio of 4 is not sufficient in the case of orthosis fitting. For fitting orthoses, an element with twelve thin layers—and thus a ratio of 144—works. But it is also possible to double the thickness of the layers, include only six layers, and the resulting element is sufficiently flexible and is able to reach a similar stiffness suitable for orthosis applications.
In order to apply a homogenous force during the compression of the different layers, as shown in
The valve 20 is inserted into the envelope 10 on the side next to the air permeable layer 50. This avoids the blocking of the airflow by a layer 30a that gets stuck to the valve orifice. Additionally the air permeable layer 50 prevents the outer layer from sticking to the envelope which could lead to loss of flexibility in the flexible state.
As indicated above, it is desirable that the layers are made of material with a high Young's modulus to make an element with a high stiffness state; but materials having a high Young's modulus usually have low extensibility. Because they are not extensible they cannot fit every 3D shape. In order to fit any 3D form or shape, especially the ones with irregular surfaces, in another possible embodiment of the invention (as shown in
In order to make the tapes—the warp 60 and weft 65 yarns—that form the layer 30f, any of the flexible layers 30, 30a, 30b, 30c, 30d or 30e of the previous embodiments are cut in tapes or ribbons of the desired width which are then woven.
In the cases where the layer is a composite material made of a polymer matrix reinforced with fibers, such as the layers 30c, 30d or 30e, of
Making the weaving smaller, i.e. with ribbons of smaller width, allows for a better fitting. For human body fitting, 3×1 twill weaving made with a tape or ribbon having a width of 4 mm and with a 1 mm gap between the tapes/ribbons gives a good result. But any ribbon's width can be used depending on the purpose.
The tapes or ribbons can be made with a fiberglass roving of 600tex (from PPG) flatted at 4 mm width. The fiber rovings are then impregnated with thermoplastic polyurethane (such as Elastollan® 890 A10 from BASF), respecting a volume ratio matrix/fiber around 30/70. In this case, the surface roughness should be around 1.27 to achieve the right friction and tackiness properties of the first and surfaces.
It is also possible to make a smaller weaving using a fiber glass roving of 300tex (from PPG) flatted at 2.5 mm width.
A preferred embodiment of the element 1 of the invention, example III, having the flexible layers 30f shown in
Regarding the weavings, many solutions are possible: plain, five-point harness, 16-point harness, 2×2 twill or 3×1 twill.
Twill weaving has the advantage of being more flexible and drapeable than plain weaving. Harness weaving is also a good option regarding drapeability.
In any case, independently of the weaving used (plain, twill, harness, . . . ) in the preferred embodiment there is a gap—of 1 mm approximately—between each ribbon in both the warp and the weft directions, in order to allow some degree of freedom between separate ribbons and thereby obtain enough drapeability to fit the human body.
The following Table 2 synthesizes the main features of the three examples I, II, Ill previously given for the layers inside the element, and their properties. In the three examples the layers of the element are enclosed in an airtight bag of PP/HDPE. The element further contains a nylon mesh for the repartition of the vacuum, adding a total of 0.6 mm to the thickness of the element.
In this text, the term “comprises” and its derivations (such as “comprising”, etc.) should not be understood in an excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc.
In the context of the present invention, the term “approximately” and terms of its family (such as “approximate”, etc.) should be understood as indicating values very near to those which accompany the aforementioned term. That is to say, a deviation within reasonable limits from an exact value should be accepted, because a skilled person in the art will understand that such a deviation from the values indicated is inevitable due to measurement inaccuracies, etc. The same applies to the terms “about” and “around” and “substantially”.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/ES2013/070177 | 3/15/2013 | WO | 00 |
