阅读说明：本技术 一种矫形器的生产工艺 (Production process of orthopedic device ) 是由 孙亚南 于 2020-05-23 设计创作，主要内容包括：本发明涉及一种矫形器的生产工艺,依次按照以下工序进行：S1,制作吸塑阳模；S2,加热塑料片材；S3,真空吸塑成型：将软化状态的塑料片材完全包覆于吸塑阳模的整个外表面,真空泵启动工作以对吸塑阳模进行抽真空处理,直至软化的塑料片材逐渐贴合于吸塑阳模的整个外表面上,最终冷却成型为初坯；S4,裁剪、打磨、打孔处理；S5,组装附属配件：打孔完成后在矫形器上装配粘扣式扎带、护垫、环扣、铰链,组装完成后进行检测工序,检测合格的矫形器包装入库。本发明利用吸塑阳模的多孔状结构实现矫形器的真空吸塑,产品的形状尺寸精度高,适用于大批量的生产的效果。(The invention relates to a production process of an orthopedic device, which is sequentially carried out according to the following procedures: s1, manufacturing a plastic suction male die; s2, heating the plastic sheet; s3, vacuum forming: the plastic sheet in a softened state is completely coated on the whole outer surface of the plastic suction male die, a vacuum pump is started to work so as to carry out vacuum pumping treatment on the plastic suction male die until the softened plastic sheet is gradually attached to the whole outer surface of the plastic suction male die, and finally the plastic sheet is cooled and formed into an initial blank; s4, cutting, polishing and punching; s5, assembling accessory accessories: and after the punching is finished, the adhesive buckle type binding belt, the protection pad, the ring buckle and the hinge are assembled on the orthosis, the detection procedure is carried out after the assembly is finished, and the qualified orthosis is packaged and put in storage. The invention realizes the vacuum forming of the orthopedic device by utilizing the porous structure of the plastic forming male die, has high shape and size precision of products and is suitable for the effect of mass production.)

1. The production process of the orthosis is characterized by comprising the following steps in sequence:

s1, manufacturing a plastic suction male die (2): the plastic material for forming is coated at the position of the human body to be shaped to form a female die, the formed female die is filled with the foaming gypsum material and is foamed to form a porous plastic suction male die (2), an exhaust pipe (3) with one end extending out of the outer side is integrally formed in the plastic suction male die (2), and the inner cavity of the exhaust pipe (3) is communicated with the hole in the plastic suction male die (2);

s2, heating the plastic sheet (1): selecting a plastic sheet (1) with the thickness of 3-7 mm, matching the size of the plastic sheet with the plastic suction male die (2), heating the plastic sheet (1) to a softening state, and preserving heat for later use;

s3, vacuum forming: the plastic sheet (1) in the softened state is completely coated on the whole outer surface of the plastic suction male die (2), redundant corners (6) of the plastic sheet (1) are mutually lapped and connected in a hot melting mode, and the outer wall of the exhaust pipe (3) is connected with the redundant corners (6) on the peripheral side of the exhaust pipe in a hot melting mode, so that the plastic sheet (1) coated on the outer side of the plastic suction male die (2) forms a sealed state; the other end of the exhaust pipe (3) is connected with a vacuum pump (5) through a pipeline (4), the vacuum pump (5) is started to work so as to vacuumize the plastic suction male die (2) until the softened plastic sheet (1) is gradually attached to the whole outer surface of the plastic suction male die (2), and finally the plastic suction male die is cooled and formed into an initial blank;

s4, cutting, polishing and punching: cutting the primary blank into an orthopedic device matched with a part to be orthopedic according to the designed size, polishing the corners and the side edges of the orthopedic device by using a polishing machine, and punching after polishing;

s5, assembling accessory accessories: and after punching is finished, assembling a sticky buckle type binding tape, a protection pad, a ring buckle and a hinge on the orthosis, carrying out a detection procedure after the assembly is finished, packaging the qualified orthosis into a warehouse, and carrying out rework treatment or scrapping treatment on the unqualified orthosis.

2. Process for the production of an orthosis according to claim 1, characterized in that: in the step S2, the plastic sheet (1) is a high-temperature thermoplastic plate, the high-temperature thermoplastic plate is flatly paved in a flat heater, heated to 180-220 ℃, and heated to a softening state.

3. Process for producing an orthosis according to claim 2, characterized in that: after the plastic sheet (1) is heated to a softening state, the thermal transfer paper with the pattern is flatly attached to the surface of the plastic sheet (1) so as to realize the thermal printing of the pattern on the surface of the plastic sheet (1).

4. Process for the production of an orthosis according to claim 1, characterized in that: in the step S2, the plastic sheet (1) is a low-temperature thermoplastic plate, the low-temperature thermoplastic plate is flatly paved in a hot water tank, the water temperature is kept at 60-80 ℃, and the plastic sheet is heated until the low-temperature thermoplastic plate is in a softened state.

5. Process for the production of an orthosis according to claim 1, characterized in that: the foaming gypsum material is prepared by fully stirring the following raw materials in parts by weight: 20-24 parts of gypsum, 3-4 parts of sodium dodecyl sulfate and 8-10 parts of water, and stirring at a rotating speed of 100-150 r/min for 10-15 min to obtain the gypsum-containing water.

6. Process for the production of an orthosis according to claim 1, characterized in that: in the step S3, the plastic suction male die (2) is wrapped with a gauze layer, one end of the exhaust tube (3) extends into the plastic suction male die (2) for 3-5 cm, and the exhaust tube (3) is a steel tube and has a diameter of 2-3 cm.

7. Process for the production of an orthosis according to claim 6, characterized in that: the suction pipe (3) is clamped and fixed through a clamping mechanism (8), the clamping mechanism (8) is fixedly installed on the operating platform (7), and the plastic suction male die (2) is cantilevered outside the operating platform (7).

8. Process for the production of an orthosis according to claim 1, characterized in that: in step S4, both ends of the blank are cut first, and then the blank is cut into two orthotics along the center line of the blank.

9. A process for the production of an orthosis according to any one of claims 1 to 8, wherein: in the step S3, two strip-shaped convex blocks (9) are fixedly adhered to the outer surfaces of the two sides of the plastic suction male die (2), the distance between the two strip-shaped convex blocks (9) on the same side is 2-4 cm, and the plastic sheet (1) is coated outside the strip-shaped convex blocks (9).

Technical Field

The invention relates to the technical field of rehabilitation engineering, in particular to a production process of an orthosis.

Background

At present, orthotics are one of the important auxiliary techniques in rehabilitation therapy of human body. Orthoses can be divided into according to the installation position: ankle-foot orthosis, trunk orthosis, upper limb orthosis. According to the statistics of the number of used ankle-foot orthoses, the ankle-foot orthoses account for 80% of the whole class of orthoses. The orthotics have basic functions of correction, protection, load avoidance and the like: correcting or preventing deformity development, limiting abnormal joint movement, improving limb function, relieving nerve compression by traction device, and relieving muscle spasm; can also fix the diseased spine and joints of four limbs, prevent contracture, relieve spasm and relieve pain; and can avoid the load bearing of limb part and promote inflammation regression, pathological changes or fracture healing.

The existing production technology of the orthotics is manual manufacturing technology which consumes physical power and consumes time, skilled orthotics technicians are needed for manufacturing the orthotics, and the orthotics are different in quality. The technician usually uses plaster bandage soaked in water to cover the corrected part of the patient according to the characteristics of the corrected part of the patient, takes the model, obtains a cavity after the plaster bandage is solidified, then fills the cavity with plaster slurry, and obtains a blank model with the same size as the corrected part after the plaster slurry is solidified. And (3) the technician carries out modification treatment on the blank according to the requirement to obtain a plaster model which can be used for manufacturing the orthosis body, and then materials such as resin, plastic plates and the like are manufactured into the orthosis worn by the patient through a complicated process means.

The above prior art solutions have the following drawbacks: the manufacturing technology of the orthosis needs a skilled orthosis technician to manually manufacture the orthosis, is time-consuming and labor-consuming, is difficult to control the product quality, and is not suitable for batch production.

Disclosure of Invention

Aiming at the defects in the prior art, the invention aims to provide a production process of an orthopedic device, which realizes vacuum forming of the orthopedic device by utilizing a porous structure of a plastic forming male die, has high shape and size precision of a product and is suitable for mass production.

The above object of the present invention is achieved by the following technical solutions:

the production process of the orthosis comprises the following steps of:

s1, manufacturing a plastic suction male die: coating a plastic material for forming at a part of a human body to be shaped to form a female die, filling a foaming gypsum material in the formed female die, forming a porous plastic suction male die through foaming and forming, integrally forming an exhaust pipe with one end extending out of the outer side in the plastic suction male die, and communicating the inner cavity of the exhaust pipe with an eyelet in the plastic suction male die;

s2, heating the plastic sheet: selecting a plastic sheet with the thickness of 3-7 mm, matching the size of the plastic sheet with a plastic suction male die, heating the plastic sheet to a softening state, and preserving heat for later use;

s3, vacuum forming: the plastic sheet in the softened state is completely coated on the whole outer surface of the plastic suction male die, redundant corners of the plastic sheet are mutually lapped and connected in a hot melting mode, and the outer wall of the exhaust pipe is connected with the redundant corners on the peripheral side of the exhaust pipe in a hot melting mode, so that the plastic sheet coated on the outer side of the plastic suction male die is in a sealed state; the other end of the exhaust pipe is connected with a vacuum pump through a pipeline, the vacuum pump is started to work so as to vacuumize the plastic suction male die until the softened plastic sheet is gradually attached to the whole outer surface of the plastic suction male die, and finally the plastic suction male die is cooled and formed into an initial blank;

s4, cutting, polishing and punching: cutting the primary blank into an orthopedic device matched with a part to be orthopedic according to the designed size, polishing the corners and the side edges of the orthopedic device by using a polishing machine, and punching after polishing;

s5, assembling accessory accessories: and after punching is finished, assembling a sticky buckle type binding tape, a protection pad, a ring buckle and a hinge on the orthosis, carrying out a detection procedure after the assembly is finished, packaging the qualified orthosis into a warehouse, and carrying out rework treatment or scrapping treatment on the unqualified orthosis.

By adopting the technical scheme, in the production process, the foaming gypsum material is foamed and molded to form the porous plastic suction male mold, and the plastic sheet in the softened state is completely coated on the whole outer surface of the plastic suction male mold to form a closed sealing state. And then the vacuum pumping treatment is carried out on the plastic suction male die through the exhaust pipe, the softened plastic sheet is gradually attached to the whole outer surface of the plastic suction male die, the plastic sheet is cooled and formed into an initial blank, and finally the cutting, polishing, punching treatment and accessory assembly are carried out. The whole production process is high in automation degree, vacuum forming of the orthotics is achieved through the porous structure of the forming male die, the formed orthotics product is high in shape and size precision, the orthotics product is suitable for mass production, and the labor cost and the input amount of raw materials are reduced.

The present invention in a preferred example may be further configured to: in the step S2, the plastic sheet is a high-temperature thermoplastic sheet, the high-temperature thermoplastic sheet is spread in a flat heater, heated to 180 to 220 ℃, and heated to a softened state.

Through adopting above-mentioned technical scheme, high temperature thermoplasticity board has higher mechanical strength, thermal stability, and the cost of manufacture is low, is convenient for produce and process.

The present invention in a preferred example may be further configured to: after the plastic sheet is heated to a softening state, the thermal transfer paper with the pattern is flatly attached to the surface of the plastic sheet, so that the thermal printing of the pattern on the surface of the plastic sheet is realized.

By adopting the technical scheme, when the plastic sheet is in a softened state, the pattern is thermally printed on the surface of the plastic sheet through the thermal transfer paper, so that the attractiveness of the overall appearance of the orthosis is enriched.

The present invention in a preferred example may be further configured to: in the step S2, the plastic sheet is a low-temperature thermoplastic sheet, the low-temperature thermoplastic sheet is spread in a hot water tank, the water temperature is kept at 60-80 ℃, and the plastic sheet is heated until the low-temperature thermoplastic sheet is in a softened state.

By adopting the technical scheme, the low-temperature thermoplastic plate can be directly shaped on the body of a wearer, the wearer can wear the thermoplastic plate more appropriately and conveniently, the mass is light, the air permeability is good, the shape fixation is fast, the disassembly is convenient, the restorability is good, the time for manufacturing the orthosis is greatly shortened, and the cost for manufacturing the orthosis is greatly reduced.

The present invention in a preferred example may be further configured to: the foaming gypsum material is prepared by fully stirring the following raw materials in parts by weight: 20-24 parts of gypsum, 3-4 parts of sodium dodecyl sulfate and 8-10 parts of water, and stirring at a rotating speed of 100-150 r/min for 10-15 min to obtain the gypsum-containing water.

By adopting the technical scheme, a large amount of gas is sucked in the stirring process to form a large amount of fine and uniform bubbles, so that the foaming gypsum material is obtained, the production period is shortened, and the raw materials are saved.

The present invention in a preferred example may be further configured to: in the step S3, the plastic suction male die is wrapped by a gauze layer, one end of the exhaust tube extends into the plastic suction male die by 3-5 cm, and the exhaust tube is a steel tube and has a diameter of 2-3 cm.

By adopting the technical scheme, the gauze layer can effectively prevent the adhesion between the surfaces of the plastic sheet and the plastic suction male die, the forming quality of the orthopedic device is ensured, and meanwhile, the connection strength between the exhaust pipe and the plastic suction male die can be ensured.

The present invention in a preferred example may be further configured to: the exhaust tube is clamped and fixed through a clamping mechanism, the clamping mechanism is fixedly installed on the operating platform, and the plastic suction male die is cantilevered outside the operating platform.

By adopting the technical scheme, the plastic suction male die is cantilevered outside the operating platform, so that the subsequent processing procedure can be facilitated, and the clamping mechanism is clamped on the exhaust tube, so that the plastic suction male die is in a fixed stable state.

The present invention in a preferred example may be further configured to: in step S4, both ends of the blank are cut first, and then the blank is cut into two orthotics along the center line of the blank.

By adopting the technical scheme, two orthotics can be simultaneously manufactured through the cutting step, and the production efficiency of the orthotics is improved.

The present invention in a preferred example may be further configured to: in the step S3, two strip-shaped convex blocks are fixedly adhered to the outer surfaces of the two sides of the plastic suction male die, the distance between the two strip-shaped convex blocks on the same side is 2-4 cm, and the plastic sheet is wrapped outside the strip-shaped convex blocks.

Through adopting above-mentioned technical scheme, the orthopedic ware forms two bars through two bar lugs and is protruding, and when the orthopedic ware was worn to the wearer, two bars were protruding can better support the orthopedic ware, are difficult to take place to rock or swing the phenomenon.

In summary, the invention includes at least one of the following beneficial technical effects:

1. in the production process, the foaming gypsum material is foamed and molded to form a porous plastic male mold, and the plastic sheet in a softened state completely covers the whole outer surface of the plastic male mold to form a closed sealing state. And then the vacuum pumping treatment is carried out on the plastic suction male die through the exhaust pipe, the softened plastic sheet is gradually attached to the whole outer surface of the plastic suction male die, the plastic sheet is cooled and formed into an initial blank, and finally the cutting, polishing, punching treatment and accessory assembly are carried out. The whole production process has high automation degree, the vacuum forming of the orthotics is realized by utilizing the porous structure of the forming male die, the shape and size precision of the formed orthotics product is high, the orthotics product is suitable for mass production, and the labor cost and the input amount of raw materials are reduced;

2. the plastic sheet has high mechanical strength and thermal stability by adopting the high-temperature thermoplastic plate, and is low in manufacturing cost and convenient to produce and process. The low-temperature thermoplastic plate can be directly molded on the body of a wearer, so that the low-temperature thermoplastic plate is more suitable and convenient to wear, light in weight, good in air permeability, fast in shape fixation, convenient to detach and good in restorability, the time for manufacturing the orthosis is greatly shortened, and the cost for manufacturing the orthosis is greatly reduced;

3. the foaming gypsum material of the invention sucks a large amount of gas in the stirring process to form a large amount of fine and uniform bubbles, the production period is shortened, and the raw materials are saved. The orthopedic device forms two strip-shaped bulges through the two strip-shaped convex blocks on the surface of the plastic suction male die, and when a wearer wears the orthopedic device, the two strip-shaped bulges can better support the orthopedic device and are not easy to shake or swing.

Drawings

FIG. 1 is a process flow diagram of the present invention.

FIG. 2 is a schematic view of vacuum forming of the present invention.

Reference numerals: 1. a plastic sheet; 2. a plastic suction male mold; 3. an air exhaust pipe; 4. a pipeline; 5. a vacuum pump; 6. a corner; 7. an operation table; 8. a clamping mechanism; 9. and a strip-shaped bump.

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings.

Referring to fig. 1, the manufacturing process of an orthosis disclosed by the invention is sequentially performed according to the following procedures:

s1, manufacturing a plastic suction male die 2: covering a plastic material for forming at a part of a human body to be orthopedic to form a female die, filling a foaming gypsum material in the formed female die, wherein the foaming gypsum material is prepared by fully stirring the following raw materials in parts by weight: 20-24 parts of gypsum, 3-4 parts of sodium dodecyl sulfate and 8-10 parts of water, and stirring at a rotating speed of 100-150 r/min for 10-15 min to obtain the gypsum-containing water. Forming a porous blister male die 2 through foaming, integrally forming an exhaust tube 3 with one end extending out of the outer side in the blister male die 2, and communicating the inner cavity of the exhaust tube 3 with the eyelet in the blister male die 2;

s2, heating the plastic sheet 1: selecting a plastic sheet 1 with the thickness of 3-7 mm, wherein the plastic sheet 1 is a high-temperature thermoplastic plate or a low-temperature thermoplastic plate, the size of the plastic sheet 1 is matched with that of the plastic suction male die 2, and after the plastic sheet 1 is heated to a softening state, preserving heat for later use;

s3, vacuum forming: referring to fig. 2, the plastic sheet 1 in a softened state is completely coated on the whole outer surface of the plastic male die 2, two strip-shaped bumps 9 are fixedly adhered to the outer surfaces of two sides of the plastic male die 2, the distance between the two strip-shaped bumps 9 on the same side is 2-4 cm, and the plastic sheet 1 is coated outside the strip-shaped bumps 9. The redundant corners 6 of the plastic sheet 1 are mutually lapped and connected in a hot melting way, and the outer wall of the exhaust pipe 3 is connected with the redundant corners 6 on the peripheral side in a hot melting way, so that the plastic sheet 1 coated on the outer side of the plastic suction male die 2 forms a sealing state; the plastic suction male die 2 is covered with a gauze layer, one end of the exhaust pipe 3 extends into the plastic suction male die 2 for 3-5 cm, and the exhaust pipe 3 is a steel pipe and has the diameter of 2-3 cm. The exhaust tube 3 is clamped and fixed through a clamping mechanism 8, the clamping mechanism 8 is fixedly installed on the operating platform 7, and the plastic suction male die 2 is suspended outside the operating platform 7. The other end of the exhaust pipe 3 is connected with a vacuum pump 5 through a pipeline 4, the vacuum pump 5 starts to work to vacuumize the plastic-absorbing male die 2 until the softened plastic sheet 1 is gradually attached to the whole outer surface of the plastic-absorbing male die 2, and finally the plastic sheet is cooled and formed into a blank;

s4, cutting, polishing and punching: cutting the two ends of the blank according to the designed size, cutting the two ends of the blank into two orthotics along the center line of the blank, cutting the orthotics into orthotics matched with the part to be orthotics, polishing the corners and the side edges of the orthotics by using a polishing machine, and punching after polishing;

s5, assembling accessory accessories: and after punching is finished, assembling a sticky buckle type binding tape, a protection pad, a ring buckle and a hinge on the orthosis, carrying out a detection procedure after the assembly is finished, packaging the qualified orthosis into a warehouse, and carrying out rework treatment or scrapping treatment on the unqualified orthosis.

When the plastic sheet 1 is a high-temperature thermoplastic plate, the high-temperature thermoplastic plate is spread in a flat heater and heated to 180-220 ℃, and the high-temperature thermoplastic plate is heated to be in a softening state. After the plastic sheet 1 is heated to a softening state, the thermal transfer paper with the pattern is flatly attached to the surface of the plastic sheet 1, so that the thermal printing of the pattern on the surface of the plastic sheet 1 is realized. When the plastic sheet 1 is a low-temperature thermoplastic plate, the low-temperature thermoplastic plate is spread in a hot water tank, the water temperature is kept at 60-80 ℃, and the low-temperature thermoplastic plate is heated until the low-temperature thermoplastic plate is in a softened state.

The implementation principle of the embodiment is as follows: in the production process of the embodiment, the foamed gypsum material is foamed and molded to form the porous blister male mold 2, and the plastic sheet 1 in the softened state completely covers the whole outer surface of the blister male mold 2 to form a closed and sealed state. And then the suction plastic male die 2 is vacuumized through the exhaust tube 3, the softened plastic sheet 1 is gradually attached to the whole outer surface of the suction plastic male die 2, is cooled and formed into a blank, and finally is cut, polished, punched and assembled with accessory accessories. A large amount of gas is sucked in the foaming gypsum material in the stirring process to form a large amount of fine and uniform bubbles, the production period is shortened, and the raw materials are saved. The orthopedic device forms two strip-shaped bulges through the two strip-shaped convex blocks 9 on the surface of the plastic suction male die 2, when a wearer wears the orthopedic device, the two strip-shaped bulges can better support the orthopedic device, and the phenomenon of shaking or swinging is not easy to occur.

The embodiments of the present invention are preferred embodiments of the present invention, and the scope of the present invention is not limited by these embodiments, so: all equivalent changes made according to the structure, shape and principle of the invention are covered by the protection scope of the invention.